Abrasive article including shaped abrasive particles

ABSTRACT

Various shaped abrasive particles are disclosed. Each shaped abrasive particle includes a body having at least one major surface and a side surface extending from the major surface.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. patent application Ser. No.15/420,701, entitled “ABRASIVE ARTICLE INCLUDING SHAPED ABRASIVEPARTICLES,” by Todd M. COTTER et al., filed Jan. 31, 2017, which isassigned to the current assignee hereof and incorporated herein byreference in its entirety.

BACKGROUND Field of the Disclosure

The following is directed to abrasive articles, and particularly,abrasive articles including shaped abrasive particles.

Description of the Related Art

Abrasive particles and abrasive articles made from abrasive particlesare useful for various material removal operations including grinding,finishing, and polishing. Depending upon the type of abrasive material,such abrasive particles can be useful in shaping or grinding a widevariety of materials and surfaces in the manufacturing of goods. Certaintypes of abrasive particles have been formulated to date that haveparticular geometries, such as triangular shaped abrasive particles andabrasive articles incorporating such objects. See, for example, U.S.Pat. Nos. 5,201,916; 5,366,523; and 5,984,988.

Three basic technologies that have been employed to produce abrasiveparticles having a specified shape are (1) fusion, (2) sintering, and(3) chemical ceramic. In the fusion process, abrasive particles can beshaped by a chill roll, the face of which may or may not be engraved, amold into which molten material is poured, or a heat sink materialimmersed in an aluminum oxide melt. See, for example, U.S. Pat. No.3,377,660 (disclosing a process including flowing molten abrasivematerial from a furnace onto a cool rotating casting cylinder, rapidlysolidifying the material to form a thin semisolid curved sheet,densifying the semisolid material with a pressure roll, and thenpartially fracturing the strip of semisolid material by reversing itscurvature by pulling it away from the cylinder with a rapidly drivencooled conveyor).

In the sintering process, abrasive particles can be formed fromrefractory powders having a particle size of up to 10 micrometers indiameter. Binders can be added to the powders along with a lubricant anda suitable solvent, e.g., water. The resulting mixture, mixtures, orslurries can be shaped into platelets or rods of various lengths anddiameters. See, for example, U.S. Pat. No. 3,079,242 (disclosing amethod of making abrasive particles from calcined bauxite materialincluding (1) reducing the material to a fine powder, (2) compactingunder affirmative pressure and forming the fine particles of said powderinto grain sized agglomerations, and (3) sintering the agglomerations ofparticles at a temperature below the fusion temperature of the bauxiteto induce limited recrystallization of the particles, whereby abrasivegrains are produced directly to size).

Chemical ceramic technology involves converting a colloidal dispersionor hydrosol (sometimes called a sol), optionally in a mixture, withsolutions of other metal oxide precursors, into a gel or any otherphysical state that restrains the mobility of the components, drying,and firing to obtain a ceramic material. See, for example, U.S. Pat.Nos. 4,744,802 and 4,848,041. Other relevant disclosures on shapedabrasive particles and associated methods of forming and abrasivearticles incorporating such particles are available at:abel-ip.com/publications/.

Still, there remains a need in the industry for improving performance,life, and efficacy of abrasive particles, and the abrasive articles thatemploy abrasive particles.

SUMMARY

According to a first aspect, a shaped abrasive particle includes a bodyincluding a first surface, a second surface, a side surface extendingbetween the first surface and second surface, and a flange portionextending from the side surface and the first major surface.

In another aspect, a shaped abrasive particle includes a body includinga first surface, a second surface, and a side surface, wherein the bodyincludes a gear-shaped two-dimensional shape including a plurality ofteeth extending peripherally from the side surface of the body.

In another aspect, a shaped abrasive particle includes a body includinga first surface, a second surface, and a side surface extending betweena first surface and the second surface, wherein the first surfaceincludes raised portions extending from exterior corners of the bodyalong the first surface and joining in a center region of the firstsurface.

In another aspect, a shaped abrasive particle includes a body defining apartial-ellipsoid shape, the body including a first surface, a secondsurface, and a third surface extending between a portion of the firstmajor surface and the second major surface, wherein at least a portionof the first surface and a portion of the second surface are connectedto each other along a first edge and wherein a portion of the firstsurface and a portion of the third surface are connected to each otherand define a second edge, and wherein a portion of the second surfaceand a portion of the third surface are connected to each other anddefine a third edge.

In another aspect, a shaped abrasive particle includes a body having aconical or frustoconical shape, wherein a surface of the body includes aplurality of protrusions extending in a spiral pathway.

In another aspect, a shaped abrasive particle includes a body defining afin-shape, wherein the body includes a length, a width and a thicknessand wherein the body includes a rectangular cross-sectional shape in theplane defined by the length and width and an elliptical cross-sectionalshape in the plane defined by the width and thickness, and wherein theaspect ratio of width-to-thickness (w:t) is at least 2:1.

In another aspect, a shaped abrasive particle includes a rake-shapedbody including a first group of projections extending from a centralregion of the body in a first direction and a second group ofprojections extending from the central region the body in a seconddirection, and wherein the first group of projections have a length(Lp1) that is different compared to a length (Lp2) of the second groupof projections.

In another aspect, a shaped abrasive particle includes a body includinga first surface, a second surface, and a side surface, wherein the bodyincludes at least four distinct side surface portions separated by atleast four exterior corners, and wherein at least one side surfaceportion includes a concave contour and wherein the particle includes acurved shape, wherein the first surface includes a substantially concavecurvature and the second surface includes a substantially convexcurvature.

In another aspect, a shaped abrasive particle includes a toothed bodyincluding a plurality of teeth extending from one side of the body,wherein the plurality of teeth define external corners of the bodyhaving an average spacing of less than 0.5(L), wherein L defines thelength of the body.

In another aspect, a shaped abrasive agglomerate includes a bodyincluding a plurality of shaped abrasive particle portions bonded toeach other to form the body of the shaped abrasive particle.

In another aspect, a shaped abrasive particle includes a body includingat least a first surface, a second surface, a third surface, and afourth surface, wherein each of the first, second, third, and fourthsurfaces contact at least one of the other first, second, third, andfourth surfaces along at least one edge of the body, and wherein thefirst surface includes a concave contour.

In another aspect, a method of making a ceramic body includes creating alayer of material from a mixture including a precursor ceramic material;altering the surface of the layer with a gaseous or liquid material tocreate a pattern in an upper surface of the layer; and forming the layerinto abrasive particles, wherein at least a portion of the abrasiveparticles includes a surface including at least a portion of the patterncreated in the upper surface of the layer.

In another aspect, a method of forming a shaped abrasive particleincludes placing a mixture including a ceramic precursor material into aproduction tool including a plurality of openings, wherein placing themixture includes partially filling a majority of the openings of theplurality of openings.

In another aspect, a shaped abrasive particle includes a body includinga plurality of discrete micro-voids distributed throughout the body,wherein the discrete micro-voids include a liquid or gas material.

In another aspect, a method of making shaped abrasive particles includestranslating a production tool having openings over rollers and through adeposition zone configured to deposit a mixture into the openings,wherein in the deposition zone the production tool is translated over aprimary roller having a greater diameter compared to any other rollersin contact with the production tool.

In another aspect, a shaped abrasive particle includes a multi-flangedbody including a first shaped abrasive portion bonded to another shapedabrasive portion to form the body including at least two differentflanges, and wherein the different flanges extend in different planeswith respect to each other.

In another aspect, a shaped abrasive particle includes an annular bodyincluding a first surface, second surface, a third surface extendingbetween the first surface and second surface, wherein the annular bodyincludes a rounded contour, a central opening extend through the body,and wherein at least a portion of the first surface includes anon-planar contour.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1 includes a portion of a system for forming a particulate materialin accordance with an embodiment.

FIGS. 2a-2b include a portion of a screen for forming a particulatematerial in accordance with an embodiment.

FIGS. 3a-3c include a portion of a screen for forming a particulatematerial in accordance with an embodiment.

FIG. 4 includes a portion of a screen for forming a particulate materialin accordance with an embodiment.

FIG. 5 includes a portion of a system for forming a particulate materialin accordance with an embodiment.

FIG. 6 includes a portion of a system for forming a particulate materialin accordance with an embodiment.

FIG. 7 includes a portion of a system for forming a particulate materialin accordance with an embodiment.

FIG. 8 includes a flow chart of a method of forming a particulatematerial in accordance with an embodiment.

FIG. 9 includes a shaped abrasive particle in accordance with anembodiment.

FIG. 10 includes a shaped abrasive particle in accordance with anembodiment.

FIG. 11 includes a shaped abrasive particle in accordance with anembodiment.

FIGS. 12a-12c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 13a-13d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 14a-14e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 15a-15g include a shaped abrasive particle in accordance with anembodiment.

FIGS. 16a-16c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 17a-17c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 18a-18e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 19a-19d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 20a-20f include a shaped abrasive particle in accordance with anembodiment.

FIGS. 21a-21e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 22a-22d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 23a-23f include a shaped abrasive particle in accordance with anembodiment.

FIGS. 24a-24f include a shaped abrasive particle in accordance with anembodiment.

FIGS. 25a-25b include a shaped abrasive particle in accordance with anembodiment.

FIGS. 26a-26c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 27a-27c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 28a-28e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 29a-29c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 30a-30d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 31a-31c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 32a-32c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 33a-33d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 34a-34d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 35a-35e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 36a-36e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 37a-37e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 38a-38f include a shaped abrasive particle in accordance with anembodiment.

FIGS. 39a-39f include a shaped abrasive particle in accordance with anembodiment.

FIGS. 40a-40c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 41a-41c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 42a-42c include a shaped abrasive particle in accordance with anembodiment.

FIGS. 43a-43d include a shaped abrasive particle in accordance with anembodiment.

FIGS. 44a-44e include a shaped abrasive particle in accordance with anembodiment.

FIGS. 45a-45e include a shaped abrasive particle in accordance with anembodiment.

DETAILED DESCRIPTION

The following is directed to abrasive articles including shaped abrasiveparticles. The methods herein may be utilized in forming shaped abrasiveparticles and using abrasive articles incorporating shaped abrasiveparticles. The shaped abrasive particles may be utilized in variousapplications, including for example fixed abrasive articles, such ascoated abrasives, bonded abrasives, non-woven abrasive materials and thelike. Alternatively, the shaped abrasive particles may be used in freeabrasives. Various other uses may be derived for the shaped abrasiveparticles.

Methods for Making Shaped Abrasive Particles

Various methods may be utilized to obtain shaped abrasive particles.Some suitable processes used to fabricate the shaped abrasive particlescan include, but is not limited to, depositing, printing (e.g.,screen-printing), molding, pressing, casting, sectioning, cutting,dicing, punching, drying, curing, coating, extruding, rolling, and acombination thereof.

Shaped abrasive particles are formed such that each particle hassubstantially the same arrangement of surfaces and edges relative toeach other for shaped abrasive particles having the same two-dimensionaland three-dimensional shapes. As such, shaped abrasive particles canhave a high shape fidelity and consistency in the arrangement of thesurfaces and edges relative to other shaped abrasive particles of thesame group having the same two-dimensional and three-dimensional shape.By contrast, non-shaped abrasive particles can be formed throughdifferent process and have different shape attributes. For example,non-shaped abrasive particles are typically formed by a comminutionprocess, wherein a mass of material is formed and then crushed andsieved to obtain abrasive particles of a certain size. However, anon-shaped abrasive particle will have a generally random arrangement ofthe surfaces and edges, and generally will lack any recognizabletwo-dimensional or three dimensional shape in the arrangement of thesurfaces and edges around the body. Moreover, non-shaped abrasiveparticles of the same group or batch generally lack a consistent shapewith respect to each other, such that the surfaces and edges arerandomly arranged when compared to each other. Therefore, non-shapedgrains or crushed grains have a significantly lower shape fidelitycompared to shaped abrasive particles.

FIG. 1 includes an illustration of a system 100 for forming a shapedabrasive particle in accordance with one, non-limiting embodiment. Asshown, the system 100 may include a die 102 in which a piston 104 maymove in order to apply a force 106 onto a mixture 108 within the die102. The resulting pressure of the force 106 may extrude the mixture 108into a tool 110 within an application zone 112. The mixture 108 may beextruded into one or more tool cavities 114 formed within the tool 110.Further, the tool 110 may be supported by a backing plate 116. In aparticular aspect, the backing plate 116 may be constructed from a lowfriction material, e.g., polytetrafluoroethylene (PTFE). In anotheraspect, it may be made of a metal or metal alloy.

The process of forming shaped abrasive particles can be initiated byforming a mixture 108 including a ceramic material and a liquid. Inparticular, the mixture 108 can be a gel formed of a ceramic powdermaterial and a liquid. In accordance with an embodiment, the gel can beformed of the ceramic powder material as an integrated network ofdiscrete particles.

The mixture 108 may contain a certain content of solid material, liquidmaterial, and additives such that it has suitable rheologicalcharacteristics for use with the process detailed herein. That is, incertain instances, the mixture can have a certain viscosity, and moreparticularly, suitable rheological characteristics that form adimensionally stable phase of material that can be formed through theprocess as noted herein. A dimensionally stable phase of material is amaterial that can be formed to have a particular shape and substantiallymaintain the shape for at least a portion of the processing subsequentto forming. In certain instances, the shape may be retained throughoutsubsequent processing, such that the shape initially provided in theforming process is present in the finally-formed object. It will beappreciated that in some instances, the mixture 108 may not be ashape-stable material, and the process may rely upon solidification andstabilization of the mixture 108 by further processing, such as drying.

The mixture 108 can be formed to have a particular content of solidmaterial, such as the ceramic powder material. For example, in oneembodiment, the mixture 108 can have a solids content of at least about25 wt %, such as at least about 35 wt %, or even at least about 38 wt %for the total weight of the mixture 108. Still, in at least onenon-limiting embodiment, the solids content of the mixture 108 can benot greater than about 75 wt %, such as not greater than about 70 wt %,not greater than about 65 wt %, not greater than about 55 wt %, notgreater than about 45 wt %, or not greater than about 42 wt %. It willbe appreciated that the content of the solids materials in the mixture108 can be within a range between any of the minimum and maximumpercentages noted above.

According to one embodiment, the ceramic powder material can include anoxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, anda combination thereof. In particular instances, the ceramic material caninclude alumina. More specifically, the ceramic material may include aboehmite material, which may be a precursor of alpha alumina. The term“boehmite” is generally used herein to denote alumina hydrates includingmineral boehmite, typically being Al₂O₃.H₂O and having a water contenton the order of 15%, as well as pseudoboehmite, having a water contenthigher than 15%, such as 20-38% by weight. It is noted that boehmite(including pseudoboehmite) has a particular and identifiable crystalstructure, and therefore a unique X-ray diffraction pattern. As such,boehmite is distinguished from other aluminous materials including otherhydrated aluminas such as ATH (aluminum trihydroxide), a commonprecursor material used herein for the fabrication of boehmiteparticulate materials.

Furthermore, the mixture 108 can be formed to have a particular contentof liquid material. Some suitable liquids may include water. Inaccordance with one embodiment, the mixture 108 can be formed to have aliquid content less than the solids content of the mixture 108. In moreparticular instances, the mixture 108 can have a liquid content of atleast about 25 wt % for the total weight of the mixture 108. In otherinstances, the amount of liquid within the mixture 108 can be greater,such as at least about 35 wt %, at least about 45 wt %, at least about50 wt %, or even at least about 58 wt %. Still, in at least onenon-limiting embodiment, the liquid content of the mixture can be notgreater than about 75 wt %, such as not greater than about 70 wt %, notgreater than about 65 wt %, not greater than about 62 wt %, or even notgreater than about 60 wt %. It will be appreciated that the content ofthe liquid in the mixture 108 can be within a range between any of theminimum and maximum percentages noted above.

Furthermore, to facilitate processing and forming shaped abrasiveparticles according to embodiments herein, the mixture 108 can have aparticular storage modulus. For example, the mixture 108 can have astorage modulus of at least about 1×10⁴ Pa, such as at least about 4×10⁴Pa, or even at least about 5×10⁴ Pa. However, in at least onenon-limiting embodiment, the mixture 108 may have a storage modulus ofnot greater than about 1×10⁷ Pa, such as not greater than about 2×10⁶Pa. It will be appreciated that the storage modulus of the mixture 108can be within a range between any of the minimum and maximum valuesnoted above.

The storage modulus can be measured via a parallel plate system usingARES or AR-G2 rotational rheometers, with Peltier plate temperaturecontrol systems. For testing, the mixture 108 can be extruded within agap between two plates that are set to be approximately 8 mm apart fromeach other. After extruding the gel into the gap, the distance betweenthe two plates defining the gap is reduced to 2 mm until the mixture 108completely fills the gap between the plates. After wiping away excessmixture, the gap is decreased by 0.1 mm and the test is initiated. Thetest is an oscillation strain sweep test conducted with instrumentsettings of a strain range between 0.01% to 100%, at 6.28 rad/s (1 Hz),using 25-mm parallel plate and recording 10 points per decade. Within 1hour after the test completes, the gap is lowered again by 0.1 mm andthe test is repeated. The test can be repeated at least 6 times. Thefirst test may differ from the second and third tests. Only the resultsfrom the second and third tests for each specimen should be reported.

Furthermore, to facilitate processing and forming shaped abrasiveparticles according to embodiments herein, the mixture 108 can have aparticular viscosity. For example, the mixture 108 can have a viscosityof at least about 2×10³ Pa s, such as at least about 3×10³ Pa s, atleast about 4×10³ Pa s, at least about 5×10³ Pa s, at least about 6×10³Pa s, at least about 8×10³ Pa s, at least about 10×10³ Pa s, at leastabout 20×10³ Pa s, at least about 30×10³ Pa s, at least about 40×10³ Pas, at least about 50×10³ Pa s, at least about 60×10³ Pa s, or at leastabout 65×10³ Pa s. In at least one non-limiting embodiment, the mixture108 may have a viscosity of not greater than about 100×10³ Pa s, such asnot greater than about 95×10³ Pa s, not greater than about 90×10 ³ Pa s,or even not greater than about 85×10³ Pa s. It will be appreciated thatthe viscosity of the mixture 108 can be within a range between any ofthe minimum and maximum values noted above. The viscosity can bemeasured in the same manner as the storage modulus as described above.

Moreover, the mixture 108 can be formed to have a particular content oforganic materials including, for example, organic additives that can bedistinct from the liquid to facilitate processing and formation ofshaped abrasive particles according to the embodiments herein. Somesuitable organic additives can include stabilizers, binders such asfructose, sucrose, lactose, glucose, UV curable resins, and the like.

Notably, the embodiments herein may utilize a mixture 108 that can bedistinct from slurries used in conventional forming operations. Forexample, the content of organic materials within the mixture 108 and, inparticular, any of the organic additives noted above, may be a minoramount as compared to other components within the mixture 108. In atleast one embodiment, the mixture 108 can be formed to have not greaterthan about 30 wt % organic material for the total weight of the mixture108. In other instances, the amount of organic materials may be less,such as not greater than about 15 wt %, not greater than about 10 wt %,or even not greater than about 5 wt %. Still, in at least onenon-limiting embodiment, the amount of organic materials within themixture 108 can be at least about 0.01 wt %, such as at least about 0.5wt % for the total weight of the mixture 108. It will be appreciatedthat the amount of organic materials in the mixture 108 can be within arange between any of the minimum and maximum values noted above.

Moreover, the mixture 108 can be formed to have a particular content ofacid or base, distinct from the liquid content, to facilitate processingand formation of shaped abrasive particles according to the embodimentsherein. Some suitable acids or bases can include nitric acid, sulfuricacid, citric acid, chloric acid, tartaric acid, phosphoric acid,ammonium nitrate, and ammonium citrate. According to one particularembodiment in which a nitric acid additive is used, the mixture 108 canhave a pH of less than about 5, and more particularly, can have a pHwithin a range between about 2 and about 4.

As shown in FIG. 1, the system 100 can include the die 102 and themixture 108 can be provided within the interior of the die 102. Further,the die 102 can be configured so that as the piston 104 moves toward thetool 110, the mixture can be extruded through a die opening 118positioned, or otherwise formed, at one end of the die 102, e.g., theend of the die 102 closest to the tool 110. As further illustrated,extruding can include applying the force 106 on the mixture 108 tofacilitate extruding the mixture 108 through the die opening 118.

During extrusion within the application zone 112, the tool 110 can be indirect contact with a portion of the die 102 to facilitate extrusion ofthe mixture 108 into the one or more tool cavities 114. The tool 110 canbe in the form of a screen, such as illustrated in FIG. 1, wherein theone or more tool cavities 114 extend through the entire thickness of thetool 110. Still, it will be appreciated that the tool 110 may be formedsuch that the one or more tool cavities 114 extend for a portion of theentire thickness of the tool 110 and have a bottom surface, such thatthe volume of space configured to hold and shape the mixture 108 isdefined by a bottom surface and side surfaces.

The tool 110 may be formed of a metal material, including for example, ametal alloy, such as stainless steel. In other instances, the tool 110may be formed of an organic material, such as a polymer.

In accordance with an embodiment, a particular pressure may be utilizedduring extrusion. For example, the pressure can be at least about 10kPa, such as at least about 500 kPa. Still, in at least one non-limitingembodiment, the pressure utilized during extrusion can be not greaterthan about 4 MPa. It will be appreciated that the pressure used toextrude the mixture 108 can be within a range between any of the minimumand maximum values noted above. In particular instances, the consistencyof the pressure delivered by a piston 199 may facilitate improvedprocessing and formation of shaped abrasive particles. Notably,controlled delivery of consistent pressure across the mixture 108 andacross the width of the die 102 can facilitate improved processingcontrol and improved dimensional characteristics of the shaped abrasiveparticles.

Prior to depositing the mixture 108 in the tool one or more toolcavities 114, a mold release agent can be applied to the surfaces of thetool one or more tool cavities 114, which may facilitate removal ofprecursor shaped abrasive particles 126 from the tool one or more toolcavities 114 after further processing. Such a process can be optionaland may not necessarily be used to conduct the molding process. Asuitable exemplary mold release agent can include an organic material,such as one or more polymers (e.g., PTFE). In other instances, an oil(synthetic or organic) may be applied as a mold release agent to thesurfaces of the tool one or more tool cavities 114. One suitable oil maybe peanut oil. The mold release agent may be applied using any suitablemanner, including but not limited to, depositing, spraying, printing,brushing, coating, and the like.

The mixture 108 may be deposited within the tool one or more toolcavities 114, which may be shaped in any suitable manner to form shapedabrasive particles having shapes corresponding to the shape of the toolone or more tool cavities 114.

Referring briefly to FIG. 2a and FIG. 2 b, FIG. 3a through 3 c, and FIG.4, various examples of tools are illustrated and designated 200, 300,and 400, respectively. As shown in these figures, the tools 200, 300,400 can include the tool one or more tool cavities 202, 302, 402, andmore particularly, a plurality of one or more tool cavities 202, 302,402 that extend into the volume of each respective tool 200, 300, 400.In accordance with these embodiments, each of the one or more toolcavities 202, 302, 402 can have a two-dimensional shape as viewed in aplane defined by the length (l) and width (w) of the respective tool200, 300, 400 in which the tool cavity 202, 302, 402 is formed.

As illustrated in FIG. 2a through FIG. 4, the tool cavities 202, 302,402 may be triangular, square with a semi-circular end, or square with asaw tooth end. In other embodiments, the tool cavities 202, 302, 402 caninclude various shapes such as, for example, polygons, ellipsoids,numerals, Greek alphabet letters, Latin alphabet letters, Russianalphabet characters, complex shapes including a combination of polygonalshapes, and a combination thereof. In particular instances, one or moretool cavities 202, 302, 402 may have two-dimensional polygonal shapessuch as a rectangle, a quadrilateral, a pentagon, a hexagon, a heptagon,an octagon, a nonagon, a decagon, and a combination thereof. Notably, aswill be appreciated in further reference to the shaped abrasiveparticles of the embodiments herein, one or more tool cavities 202, 302,402 may utilize various other shapes. Further, as indicated in FIG. 2athrough FIG. 4, in certain instances, during extrusion, the toolcavities 202, 302, 402 may be partially filled in order to create shapesthat only partially correspond to the interior shape of the respectivetool cavities 202, 302, 402.

In such a case, a method for forming shaped abrasive particles mayinclude placing a mixture 206, 306, 406 comprising a ceramic precursormaterial into a production tool having a plurality of openings, e.g.,one of the tools 200, 300, 400 described herein having the respectivetool cavities 202, 302, 402. Placing the mixture 206, 306, 406 comprisespartially filling a majority of the cavities of the plurality ofcavities. In certain instances, each of the plurality of tool cavities202, 302, 402 formed in the production tools 200, 300, 400 can have thesame two-dimensional shape or different two-dimensional shapes.

In another aspect, partially filling includes placing the mixture 206,306, 406 into only a portion of the openings such that the openingscomprise some mixture 206, 306, 406 and some void volume that is free ofthe mixture. Partially filling a majority of the openings can includecontrolling at least one variable from the group consisting of:orientation of the plurality of openings relative to a direction oftranslation of the production tool, speed of translation of theproduction tool, viscosity of the mixture, pressure applied to themixture during placing of the mixture into the plurality of openings,material of the production tool, surface energy between the surface ofthe plurality of the openings and the mixture, and any combinationthereof.

Each tool 200, 300, 400 as illustrated may include a plurality of toolcavities 202, 302, 402 oriented in a particular manner relative to eachother. For example, each of the plurality of tool cavities 202, 302, 402in each respective tool 200, 300, 400 can have substantially the sameorientation relative to each other, and substantially the sameorientation relative to the surface of the screen. However, it will beappreciated, that in other instances, the one or more tool cavities 202,302, 402 within each tool 200, 300, 400 need not necessarily have thesame orientation relative to each other.

Referring again to FIG. 1, during operation of the system 100, the tool110 can be translated in a direction 120 to facilitate a continuousmolding operation. As will be appreciated, the tool 110 may be in theform of a continuous belt, which can be translated over rollers tofacilitate continuous processing. In some embodiments, the tool 110 canbe translated while extruding the mixture 108 through the die opening118. As illustrated in the representation of the system 100, the mixture108 may be extruded in a direction 122. The direction of translation 120of the tool 110 can be angled relative to the direction of extrusion 122of the mixture 108. While the angle between the direction of translation120 and the direction of extrusion 122 is illustrated as substantiallyorthogonal in the system 100, other angles are contemplated, includingfor example, an acute angle or an obtuse angle. After the mixture 108 isextruded through the die opening 118, the mixture 108 and tool 110 maybe translated under a knife edge 124 attached to, or otherwise formedon, a surface of the die 102. The knife edge 124 may define a region atthe front of the die 102 that facilitates displacement of the mixture108 into the tool one or more tool cavities 114 of the tool 110.

In the molding process, the mixture 108 may undergo significant dryingwhile contained in the tool cavity 114. Therefore, shaping may beprimarily attributed to substantial drying and solidification of themixture 108 in the tool one or more tool cavities 114 to shape themixture 108.

After applying the mold release agent, the mixture 108 can be depositedwithin the mold cavities and dried. Drying may include removal of aparticular content of certain materials from the mixture 108, includingvolatiles, such as water or organic materials. In accordance with anembodiment, the drying process can be conducted at a drying temperatureof not greater than about 300° C., such as not greater than about 250°C., not greater than about 200° C., not greater than about 150° C., notgreater than about 100° C., not greater than about 80° C., not greaterthan about 60° C., not greater than about 40° C., or even not greaterthan about 30° C. Still, in one non-limiting embodiment, the dryingprocess may be conducted at a drying temperature of at least about −20°C., such as at least about −10° C. at least about 0° C. at least about5° C. at least about 10° C., or even at least about 20° C. It will beappreciated that the drying temperature may be within a range betweenany of the minimum and maximum temperatures noted above.

In certain instances, drying may be conducted for a particular durationto facilitate the formation of shaped abrasive particles according toembodiments herein. For example, drying can be conducted for a durationof at least about 20 second, such as at least about 1 minute, at leastabout 2 minutes, at least about 4 minutes, at least about 6 minutes, atleast about 8 minutes, at least about 10 minutes, at least about 30minutes, at least about 1 hour, at least about 2 hours, at least about 4hours, at least about 8 hours, at least about 12 hours, at least about15 hours, at least about 18 hours, at least about 24 hours. In stillother instances, the process of drying may be not greater than about 30hours, such as not greater than about 24 hours, not greater than about20 hours, not greater than about 15 hours, not greater than about 12hours, not greater than about 10 hours, not greater than about 8 hours,not greater than about 6 hours, not greater than about 4 hours. It willbe appreciated that the duration of drying can be within a range betweenany of the minimum and maximum values noted above.

Additionally, drying may be conducted at a particular relative humidityto facilitate formation of shaped abrasive particles according to theembodiments herein. For example, drying may be conducted at a relativehumidity of at least about 20%, at least about 30%, at least about 40%,at least about 50%, at least about 60%, such as at least about 62%, atleast about 64%, at least about 66%, at least about 68%, at least about70%, at least about 72%, at least about 74%, at least about 76%, atleast about 78%, or even at least about 80%. In still other non-limitingembodiments, drying may be conducted at a relative humidity of notgreater than about 90%, such as not greater than about 88%, not greaterthan about 86%, not greater than about 84%, not greater than about 82%,not greater than about 80%, not greater than about 78%, not greater thanabout 76%, not greater than about 74%, not greater than about 72%, notgreater than about 70%, not greater than about 65%, not greater thanabout 60%, not greater than about 55%, not greater than about 50%, notgreater than about 45%, not greater than about 40%, not greater thanabout 35%, not greater than about 30%, or even not greater than about25%. It will be appreciated that the relative humidity utilized duringdrying can be within a range between any of the minimum and maximumpercentages noted above.

After completing the drying process, the mixture 108 can be releasedfrom the tool one or more tool cavities 114 to produce precursor shapedabrasive particles 126. Notably, before the mixture 108 is removed fromthe tool one or more tool cavities 114 or after the mixture 108 isremoved and the precursor shaped abrasive particles 126 are formed, oneor more post-forming processes may be completed. Such processes caninclude surface shaping, curing, reacting, radiating, planarizing,calcining, sintering, sieving, doping, and a combination thereof. Forexample, in one optional process, the mixture 108 or precursor shapedabrasive particles 126 may be translated through an optional shapingzone, wherein at least one exterior surface of the mixture or precursorshaped abrasive particles 126 may be shaped.

In still another embodiment, the mixture 108 as contained in the moldcavities or the precursor shaped abrasive particles 126 may betranslated through an optional application zone, wherein a dopantmaterial can be applied. In particular instances, the process ofapplying a dopant material can include selective placement of the dopantmaterial on at least one exterior surface of the mixture 108 orprecursor shaped abrasive particles. In an optional process, the mixture108 may be treated with one or more acid or base materials. Treatmentmay occur post-calcination and may affect a distribution of dopantmaterial within the shaped abrasive particle. In a particular instance,treatment with one or more acid or base materials may facilitateincreased performance of the shaped abrasive particle. The process ofapplying a dopant can include doping (i.e., additives or a provision ofadditives to the gel prior to calcination). In alternative instances, animpregnation process may be used instead of doping, where impregnationutilizes an additive introduced to the precursor particles aftercalcination. Utilization of doping or impregnation may affectdistribution of the dopant material within the final shaped abrasiveparticle which may also facilitate increased performance of the shapedabrasive particle.

The dopant material may be applied utilizing various methods includingfor example, spraying, dipping, depositing, impregnating, transferring,punching, cutting, pressing, crushing, and any combination thereof. Inaccordance with an embodiment, applying a dopant material can includethe application of a particular material, such as a precursor. Incertain instances, the precursor can be a salt, such as a metal salt,that includes a dopant material to be incorporated into thefinally-formed shaped abrasive particles. For example, the metal saltcan include an element or compound that is the precursor to the dopantmaterial. It will be appreciated that the salt material may be in liquidform, such as in a dispersion comprising the salt and liquid carrier.The salt may include nitrogen, and more particularly, can include anitrate. In other embodiments, the salt can be a chloride, sulfate,phosphate, and a combination thereof. In one embodiment, the salt caninclude a metal nitrate, and more particularly, consist essentially of ametal nitrate. In one embodiment, the dopant material can include anelement or compound such as an alkali element, alkaline earth element,rare earth element, hafnium, zirconium, niobium, tantalum, molybdenum,vanadium, or a combination thereof. In one particular embodiment, thedopant material includes an element or compound including an elementsuch as lithium, sodium, potassium, magnesium, calcium, strontium,barium, scandium, yttrium, lanthanum, cesium, praseodymium, niobium,hafnium, zirconium, tantalum, molybdenum, vanadium, chromium, cobalt,iron, germanium, manganese, nickel, titanium, zinc, and a combinationthereof.

The forming process may further include a sintering process. For certainembodiments herein, sintering can be conducted after removing themixture from the tool one or more tool cavities 114 and forming theprecursor shaped abrasive particles 126. Sintering of the precursorshaped abrasive particles 126 may be utilized to densify the particles126, which are generally in a green state. In a particular instance, thesintering process can facilitate the formation of a high-temperaturephase of the ceramic material. For example, in one embodiment, theprecursor shaped abrasive particles may be sintered such that ahigh-temperature phase of alumina, such as alpha alumina, is formed. Inone instance, a shaped abrasive particle can comprise at least about 90wt % alpha alumina for the total weight of the particle. In otherinstances, the content of alpha alumina may be greater such that theshaped abrasive particle may consist essentially of alpha alumina.

The body of the finally-formed shaped abrasive particles can haveparticular two-dimensional shapes. For example, the body can have atwo-dimensional shape, as viewed in a plane defined by the length andwidth of the body, and can have a shape including a polygonal shape,ellipsoidal shape, a numeral, a Greek alphabet character, a Latinalphabet character, a Russian alphabet character, a complex shapeutilizing a combination of polygonal shapes and a combination thereof.Particular polygonal shapes include rectangular, trapezoidal,pentagonal, hexagonal, heptagonal, octagonal, nonagonal, decagonal, andany combination thereof. In another instance, the finally-formed shapedabrasive particles can have a body having a two-dimensional shape suchas an irregular quadrilateral, an irregular rectangle, an irregulartrapezoid, an irregular pentagon, an irregular hexagon, an irregularheptagon, an irregular octagon, an irregular nonagon, an irregulardecagon, and a combination thereof. An irregular polygonal shape is onewhere at least one of the sides defining the polygonal shape isdifferent in dimension (e.g., length) with respect to another side. Asillustrated in other embodiments herein, the two-dimensional shape ofcertain shaped abrasive particles can have a particular number ofexterior points or external corners. For example, the body of the shapedabrasive particles can have a two-dimensional polygonal shape as viewedin a plane defined by a length and width, wherein the body comprises atwo-dimensional shape having at least 4 exterior points (e.g., aquadrilateral), at least 5 exterior points (e.g., a pentagon), at least6 exterior points (e.g., a hexagon), at least 7 exterior points (e.g., aheptagon), at least 8 exterior points (e.g., an octagon), at least 9exterior points (e.g., a nonagon), and the like.

Referring now to FIG. 5, another system 500 for forming shaped abrasiveparticles in accordance with one, non-limiting embodiment isillustrated. As shown, the system 500 may include a die 502 having apiston 504 disposed therein. The piston 504 may move within the die 502in order to apply a force 506 onto a mixture 508 also disposed withinthe die 502 between the piston 504 and a shaped die opening 510.

The resulting pressure of the force 506 may extrude the mixture 508through the shaped die opening 510 and onto a conveyor belt 512. Theconveyor belt 512 may be supported by, and rotate on, a first roller 514and a second roller 516. In a particular embodiment, the mixture 508 canbe same as the mixture 108, described above. Further, the mixture 508can be extruded from the die 502 and a resulting extrudate 520 canundergo one or more post-forming processes, described above, to become ashaped abrasive particle having the shape of the shaped die opening 510.

In another aspect, the system 500 can further include a post-extrusionshaping device 522. The post-extrusion shaping device 522 may be astamping device, a molding device, a pressing device, or some otherdevice that may be used to alter, or otherwise modify, the shape of theextrudate 520 into another shape. For example, the post-extrusionshaping device 522 may include a piston driven stamp 524. The extrudate520 may be moved into position under the post-extrusion shaping device522 and the piston driven stamp 524 may be lowered onto the extrudate520 in order to press the extrudate 520 into a stamped extrudate 526having a different shape than that of the extrudate 520 after it isextruded onto the conveyor belt 512 from the die 502. Thereafter, thestamped extrudate 526 may undergo one or more of the post-formingprocesses described above to become a shaped abrasive particle having ashape corresponding to the interior shape of the piston driven stamp524. It can be appreciated that the extrudate 520 or the stampedextrudate 526 can be shaped like one or more of the shaped abrasiveparticles described in detail herein. The stamp may be used to form allor a portion of the features of a shaped abrasive particle. For example,in certain instances, the stamp may be used to form a shaped abrasiveparticle having a particular shape from the extrudate. In still otherinstances, the stamp may be used to form only a portion of theextrudate, such as a surface of the extrudate, such that the stamp isconfigured to impart one or more surface features to the extrudate. Infurther instances, the extrudate 520 can be in the form of a ribbon, andthe post-extrusion shaping device 522 and/or the piston driven stamp 524can be used to stamp a shape (e.g., a shaped abrasive particle having ashape corresponding to the interior shape of the piston driven stamp524) out of the ribbon.

The stamp can be used with other processes, such as a molding process ora screen printing process to alter a portion (e.g. a surface) of theprecursor shaped abrasive particles made by printing or molding.

FIG. 6 illustrates yet another system 600 for forming shaped abrasiveparticles in accordance with one, non-limiting embodiment isillustrated. As illustrated in FIG. 6, the system 600 may include a die602 having a piston 604 disposed therein. The piston 604 may move withinthe die 602 in order to apply a force 606 onto a mixture 608 alsodisposed within the die 602 between the piston 604 and a die opening610.

The resulting pressure of the force 606 may extrude the mixture 608through the die opening 610 and onto a conveyor belt 612. The conveyorbelt 612 may be supported by, and rotate on, a first roller 614, asecond roller 616, and a third roller 618. The third roller 618 may beplaced directly under the die 602 so that when the mixture 608 isextruded from the die 602, the extrusion force will not move theconveyor belt 612 away from the die 602. In a particular embodiment, themixture 608 can be same as the mixture 108, described above.

As illustrated in the enlarged portion of FIG. 6, the conveyor belt 612can include an exterior layer 620 and an interior layer 622. Theexterior layer 620 may be constructed from a low friction material,e.g., PTFE, while the interior layer 622 may be constructed from a highfriction material, e.g., rubber. The exterior layer 620 acts as a toollayer and can include a plurality of tool cavities 624. Duringoperation, the mixture 608 can be extruded from the die 602 and into thetool cavities 624 formed in the exterior layer 620 of the conveyor belt612. After the mixture 608 is extruded from the die 602 into the toolcavities 624 of the exterior layer 620 of the conveyor belt 612, thematerial within the tool cavities 624 may undergo one or morepost-forming processes, described above, to become a shaped abrasiveparticle having the shape of the tool cavities 624. The tool cavities624 may have an interior shape that corresponds to the exterior shape ofone or more of the shaped abrasive particles described herein. It can beappreciated that the exterior layer 620 of the conveyor belt 612 canhave a coefficient of friction low enough to allow the shaped abrasiveparticles 626 to release from the conveyor belt 612 as the conveyor belt612 rotates around and under the rollers 614, 616, 618. Further, theinterior layer 622 of the conveyor belt 612 can have a coefficient offriction high enough to engage the rollers 614, 616, 618 and allow theconveyor belt 612 to be driven by one or more of the rollers 614, 616,618 and not slide relative to those rollers 614, 616, 618 duringoperation. FIG. 6 further indicates that the system 600 may include adrying device 630 that may be used to cure, or otherwise dry, thematerial 608 after it is extruded into the tool cavities 624 formed inthe conveyor belt 612.

The system 600 illustrated in FIG. 6 may be used in a method of makingshaped abrasive particles that includes translating a production toolhaving openings over rollers and through a deposition zone configured todeposit a mixture into the openings. In the deposition zone, theproduction tool is translated over a primary roller having a greaterdiameter compared to any other roller in contact with the productiontool.

Referring to FIG. 7, an illustration of still another system 700 forforming a shaped abrasive particle in accordance with one, non-limitingembodiment. As shown, the system 700 may include a die 702 in which apiston 704 may move in order to apply a force 706 onto a mixture 708within the die 702. The resulting pressure of the force 706 may extrudethe mixture 708 into a tool 710, e.g., a screen, within an applicationzone 712. The mixture 708 may be extruded into one or more tool cavities714 formed within the tool 710. Further, the tool 710 may be supportedby a backing plate 716. In a particular aspect, the backing plate 716may be constructed from a low friction material, e.g.,polytetrafluoroethylene (PTFE).

As shown in FIG. 7, the die 702 can be configured so that as the piston704 moves toward the tool 710, the mixture can be extruded through a dieopening 718 positioned, or otherwise formed, at one end of the die 702,e.g., the end of the die 702 closest to the tool 710.

During extrusion within the application zone 712, the tool 710 can be indirect contact with a portion of the die 702 to facilitate extrusion ofthe mixture 708 into the one or more tool cavities 714. However, aportion of the tool cavity 714 may be positioned outside of theapplication zone 712 to allow a portion of the mixture 708 to beextruded through and out of the tool cavity 714. The portion of themixture 708 that is allowed to overflow the tool cavity 714 may form alip or other structure on a shaped abrasive particle, as described indetail herein, when the tool 710, e.g., the screen, is peeled away fromthe backing plate 716 as illustrated in FIG. 7.

After the mixture 708 is extruded through the die opening 718, themixture 708 and tool 710 may be translated under a knife edge 724attached to, or otherwise formed on, a surface of the die 702. The knifeedge 724 may define a region at the front of the die 702 thatfacilitates displacement of the mixture 708 into the tool one or moretool cavities 714 of the tool 710. It can be appreciated that after thematerial 708 is extruded into and through the tool cavity 714, thematerial may undergo one or more of the post-forming processes,described above, to become a shaped abrasive particle having the shapeof the tool cavity 714 and the overflow portion.

Referring now to FIG. 8, a method of forming a shaped abrasive particlein accordance with one, non-limiting embodiment, is illustrated and isgenerally designated 800. As depicted, the method 800 can includeforming an abrasive sheet with a plurality of predetermined voids (e.g.,pores) at step 802. The abrasive sheet may be formed using a screenprinting process or a molding process. Further, the voids may be formedby including a volatile component in the mixture that burns off duringthe firing process leaving behind the voids. At step 804, the method 800may include curing the abrasive sheet 804. Moreover, the method 800 mayinclude fracturing the abrasive sheet through the voids to createabrasive grains at step 806. Thereafter, at step 808, the method 808 mayinclude sorting the abrasive grains.

FIGS. 9-12 c illustrate various shaped abrasive particles formed with aplurality of voids. The voids can be discrete micro-voids that can bedistributed throughout a body, such as uniformly distributed throughoutthe volume of the body. The discrete micro-voids can include a liquid orgas material. Further, the discrete micro-voids can be non-uniformlydistributed through a particular body. As such, a particular body caninclude a greater content of discrete micro-voids in a central region ofthe body compare to a content of discrete micro-voids at a surfaceregion of the body.

In another aspect, the discrete micro-voids can be uniformly distributedthroughout the body, or sheet. Moreover, the discrete micro-voids can benon-homogenously distributed so that there are more voids in thickerparts of a body and less near edges of the body. The voids can becreated by coating precursor abrasive particles with a second layer ordouble extruding two different types of mixtures. The micro-voids mayalso be formed by a subtractive process, including the use of one ormore pore formers.

FIG. 9 illustrates an abrasive particle 900 having a body 902 formedwith a first void 904, a second void 906, and a third void 908. Asshown, the voids 904, 906, 908 are shaped like circles. However, thevoids 904, 906, 908 can be shaped like a triangle, a square, afive-point star, a diamond, a hexagon, a four-point star, or any otherregular or irregular polygonal shape. FIG. 10 depicts an abrasiveparticle 1000 having a body 1002 formed with a first void 1004, a secondvoid 1006, a third void 1008, a fourth void 1010, and a fifth void 1012.As shown, the voids 1004, 1006, 1008, 1010 are shaped like circles.However, the voids 1004, 1006, 1008, 1010 can be shaped like a triangle,a square, a five-point star, a diamond, a hexagon, a four-point star, orany other regular or irregular polygonal shape. FIG. 11 depicts yetanother abrasive particle 1100 having a body 1102 formed with a firstvoid 1104, a second void 1106, a third void 1108, a fourth void 1110,and a fifth void 1112. As shown, the voids 1104, 1106, 1108, 1110, 1112can be shaped like circles. However, the voids 1104, 1106, 1108, 1110,1112 can be shaped like a triangle, a square, a five-point star, adiamond, a hexagon, a four-point star, or any other regular or irregularpolygonal shape. It can be appreciated that while the various voidsformed in the abrasive particles 900, 1000, 1100 described inconjunction with FIG. 9 through FIG. 11, those voids may be formed withany other shape. For example, the voids can include any other complexshapes including a combination of polygonal shapes, and a combinationthereof. In particular instances, the voids may have two-dimensionalpolygonal shapes such as a rectangle, a quadrilateral, a pentagon, ahexagon, a heptagon, an octagon, a nonagon, a decagon, and a combinationthereof. Additionally, the voids may have amorphous shapes that do notcorrespond to polygonal shapes. Further, the abrasive particles 900,1000, 1100 may include any number of voids formed therein. Those voidsmay be oriented in a grid pattern or they may be oriented in no formalpattern. Further, the abrasive particles 900, 1000, 1100 may be formedusing one or more of the processes described herein prior to fracturingthe abrasive particles 900, 1000, 1100, through the voids.

FIG. 12a shows another abrasive particle 1200 that includes a body 1202formed with a keyhole, or vase, shaped void 1204. FIG. 12b indicatesthat the abrasive particle 1200 may be fractured through or near thevoid 1204 along a crack 1206 to yield a major portion 1208 and a minorportion 1210. As indicated in FIG. 12 c, the minor portion 1210 may beremoved after the fracturing operation, e.g., using a sieving operation.As such, the major portion 1208 may remain and may include one or morerelatively sharp edges 1212 adjacent to, or flanking, the void 1204.

Shaped Abrasive Particles

Referring to FIG. 13a through 13 d, a shaped abrasive particle inaccordance with an embodiment is shown and is generally designated 1300.FIG. 13a includes a perspective view of the shaped abrasive particle1300. FIG. 13b includes a side plan view of the shaped abrasive particle1300 and FIG. 13c includes a top plan view of the shaped abrasiveparticle 1300. The bottom plan view is the same as the top plan view.

As illustrated, the shaped abrasive particle 1300 includes a body 1302that includes a first surface 1304 and a second surface 1306 oppositethe first surface 1304. As depicted, a side surface 1308 can extendbetween the first surface 1304 and the second surface 1306. FIGS. 13athrough FIG. 13c show that the body 1302 can be generally gear-shaped,i.e., the plan view of the body 1302 (the two-dimensional shape) caninclude a plurality of teeth 1310 extending peripherally from the sidesurface 1308 of the body 1302.

In a particular aspect, the teeth 1310 can extend along a length of thebody 1302. Further, the teeth 1310 can extend along the entire length ofthe body 1302. As indicated in FIG. 13c , each of the plurality of teeth1310 can include a two-dimensional shape. The two-dimensional shape ofeach tooth 1310 can be symmetric about an axis 1312 that bisects eachtooth 1310. In another aspect, the two-dimensional shape of each tooth1310 may be asymmetric about the axis 1312.

As indicated in FIG. 13a through FIG. 13 c, the teeth 1310 aresubstantially identical. In other aspects, the teeth 1310 may havedifferent shapes. In other words, some of the teeth 1310 may besymmetric about the axis 1312 while other teeth 1310 are asymmetricabout the axis 1312. Further, some teeth 1310 may have tooth height1314, i.e., a distance from a center 1316 of the shaped abrasive grain1300, that is different from other teeth 1310, so that some teeth 1310extend a greater distance from the side surface 1308 than other teeth1310 (as illustrated in FIG. 13d ). In a particular aspect, the shapedabrasive particle 1300 can be formed using one or more of the systemsand methods, described herein.

FIG. 14a through FIG. 14e illustrate a shaped abrasive particle 1400 inaccordance with an embodiment. FIG. 14a includes a perspective view ofthe shaped abrasive particle 1400. FIG. 14b includes a front plan viewof the shaped abrasive particle 1400. The back plan view of the shapedabrasive particle 1400 is the same as the front plan view. FIG. 14cincludes a side plan view of the shaped abrasive particle 1400. Bothsides of the shaped abrasive particle 1400 are the same in the planview. FIG. 14d includes a top plan view of the shaped abrasive particle1400 and FIG. 14e includes a bottom plan view of the shaped abrasiveparticle 1400.

As indicated, the shaped abrasive particle 1400 includes a body 1402having a first surface 1404 and a second surface 1406 distanced from thefirst surface 1404. A side surface 1408 can extend between the firstsurface 1404 and the second surface 1406.

As depicted in FIG. 14a through FIG. 14 e, the body 1402 of the shapedabrasive particle 1400 can be generally triangular and can include threeexterior corners 1410. The first surface 1404 and the second surface1406 can each include a raised portion 1412 that can extend from eachexterior corner 1410 to the center 1414 of the body 1402. The raisedportions 1412 can join each other in the center region of the firstsurface 1404 and the second surface 1406, respectively. In a particularaspect, the raised portions 1412 can extend linearly from the exteriorcorners 1410 to the center 1414 region of the body 1402. As more clearlyindicated in FIG. 14b , the raised portions 1412 can define and separatea plurality of depressed regions 1416 that can abut the raised portionsand at least a portion of the side surface 1408 of the body 1402. Inother words, each depressed region 1416 is bounded by two adjacentraised portions 1412 and a portion of the side surface 1408 of the body1402. The raised portions 1412 on the first surface 1404 and the secondsurface 1406 can have substantially the same arrangement to each other.In a particular aspect, the shaped abrasive particle 1400 can be formedusing one or more of the systems and methods, described herein.

FIG. 15a through FIG. 15e includes a shaped abrasive particle 1500 inaccordance with an embodiment. FIG. 15a includes a perspective view ofthe shaped abrasive particle 1500. FIG. 15b includes a front plan viewof the shaped abrasive particle 1500. FIG. 15c includes a side plan viewof the shaped abrasive particle 1500. Both sides of the shaped abrasiveparticle 1500 are the same in plan view. FIG. 15d includes a top planview of the shaped abrasive particle 1500 and FIG. 15e includes a bottomplan view of the shaped abrasive particle 1500.

As illustrated, the shaped abrasive particle 1500 can include a body1502 having a partial-ellipsoid shape. The body 1502 can include a firstmajor surface 1504 and a second major surface 1506 jointed by a thirdsurface 1508 that can extend between at least a portion of the firstmajor surface 1504 and the second major surface 1506. The third surface1508 can be generally arch shaped. The body 1502 can include a fourthsurface 1510 that can extend between at least a portion of the firstmajor surface 1504, the second major surface 1506, and the third surface1508. The fourth surface 1510 can act as a base and as indicated in FIG.15 e, the fourth surface 1510 can be generally elliptical in shape. Incertain instances, the body 1502 can have a partial-ellipsoid shape ononly one major surface (e.g., either the first major surface 1504 or thesecond major surface 1506 can include a degree of curvature).

As depicted in FIG. 15 b, the first major surface 1504 can connect tothe third surface 1508 along a first edge 1512. The second major surface1506 can also connect to the third surface 1508 along a second edge1514. The second edge 1514 can be opposite the first edge 1512. Thefourth surface 1510 can connect to the first major surface 1504, thesecond major surface 1506, and the third surface 1508 along a third edge1516.

In a particular aspect, the first major surface 1504 can include aconvex shape. In another aspect, the first major surface 1504 caninclude a concave shape, as illustrated in FIG. 15 f. In still anotheraspect, the first major surface 1504 can include a flat, planar shape,as illustrated in FIG. 15 g. Similarly, the second major surface 1506can include a concave shape, a convex shape, a planar shape, or acombination thereof. The third surface 1508 can be include an archshape, as indicated in FIG. 15c and the fourth surface 1510 can includea planar shape. However, in another aspect, the fourth surface 1510 canalso include a concave shape. The first edge 1512 and the second edge1514 can include a curved or elliptical contour. The third edge 1616 canalso include a curved or elliptical contour.

In a particular aspect, the first major surface 1504 and the secondmajor surface 1506 may both include a convex shape. In another aspect,the first major surface 1504 and the second major surface 1506 may bothinclude a concave shape. In another aspect, the first major surface 1504may be include a convex shape while the second major surface 1506includes a concave shape (or vice versa). In still another aspect, thefirst major surface 1504 can include a planar shape and the second majorsurface 1506 may both include a convex shape or a concave shape. Or, thesecond major surface 1506 may include a planar shape and the first majorsurface 1504 can include a convex shape or a concave shape. In aparticular aspect, the shaped abrasive particle 1500 can be formed usingone or more of the systems and methods, described herein.

FIG. 16a through FIG. 16c include a shaped abrasive particle 1600 inaccordance with an embodiment. FIG. 16a includes a side plan view of theshaped abrasive particle 1600. FIG. 16b includes a top plan view of theshaped abrasive particle 1600 and FIG. 16c includes a bottom plan viewof the shaped abrasive particle 1600.

As shown, the shaped abrasive particle 1600 can have a body 1602 that isgenerally frustoconical in shape. The body 1602 can include a firstsurface 1604 and a second surface 1606 that is substantially parallel tothe first surface 1604. An angled side surface 1608 can extend betweenthe first surface 1604 and the second surface 1606. The side surface1608 can include a plurality of protrusions 1610 that can extend betweenthe first surface 1604 and the second surface 1606 along a spiralpathway. As indicated in FIG. 16 b, the protrusions 1610 can be equallyspaced around a center 1612 of the body 1602. In a particular aspect,the shaped abrasive particle 1600 can be formed using one or more of thesystems and methods, described herein.

FIG. 17a through FIG. 17c include a shaped abrasive particle 1700 inaccordance with an embodiment. FIG. 17a includes a side plan view of theshaped abrasive particle 1700. FIG. 17b includes a top plan view of theshaped abrasive particle 1700 and FIG. 17c includes a bottom plan viewof the shaped abrasive particle 1700.

As shown, the shaped abrasive particle 1700 can have a body 1702 that isgenerally conical in shape. The body 1702 can include a vertex 1704 anda surface 1706 that is spaced a distance from the vertex 1704. An angledside surface 1708 can extend between the vertex 1704 and the surface1706. The side surface 1708 can include a plurality of protrusions 1710that can extend between the vertex 1704 and the surface 1706 along aspiral pathway. As indicated in FIG. 17 b, the protrusions 1710 can beequally spaced around a center 1712 of the body 1702. In a particularaspect, the shaped abrasive particle 1700 can be formed using one ormore of the systems and methods, described herein.

FIG. 18a through FIG. 18e include a shaped abrasive particle 1800 inaccordance with an embodiment. FIG. 18a includes a perspective view ofthe shaped abrasive particle 1800. FIG. 18b includes a front plan viewof the shaped abrasive particle 1800. The back plan view of the shapedabrasive particle 1800 is the same as the front plan view. FIG. 18cincludes a side plan view of the shaped abrasive particle 1800. Bothsides of the shaped abrasive particle 1800 are the same in plan view.FIG. 18d includes a top plan view of the shaped abrasive particle 1800and FIG. 18e includes a bottom plan view of the shaped abrasive particle1800.

As illustrated, the shaped abrasive particle 1800 includes a body 1802attached to a base 1804. The body 1802 is generally fin-shaped andincludes a length 1806, a width 1808, and a thickness 1808.

In a particular aspect, the body 1802 includes a rectangularcross-sectional shape in a plane defined by the length 1806 and thewidth 1808. Further, the body 1802 has a generally ellipticalcross-sectional shape in a plane defined by the width 1808 and thickness1810. In a particular aspect, an aspect ratio of the width 1808 to thethickness 1810 (w:t) is at least 2:1, such as at least 3:1, at least4:1, at least 5:1, or at least 6:1. Further, in a particular aspect, w:tis no greater than 20:1, such as no greater than 15:1, no greater than12:1, or no greater than 10:1.

In a particular aspect, the base 1804 of the shaped abrasive particle1800 includes a diameter 1812 and a ratio of the diameter 1812 of thebase 1804 to the width 1808 of the body 1802 (d:w) is at least 1:1, suchas at least 2:1, at least 3:1, or at least 4:1. In another aspect, d:wis no greater than 10:1, no greater than 8:1, or no greater than 5:1.

As depicted, the body 1802 shaped abrasive particle 1800 includes afirst surface 1814 and a second surface 1816 distanced therefrom. A sidesurface 1818 extends between the first surface 1814 and the secondsurface 1816. The side surface 1818 includes two side surface portions1820 having a planar shape and two side surface portions 1822 having aconvex shape. The two side portions 1822 having the convex shape areseparated from each other by the two side portions 1820 having theplanar shape. In a particular aspect, the shaped abrasive particle 1800can be formed using one or more of the systems and methods, describedherein.

FIG. 19a through FIG. 19d include a shaped abrasive particle 1900 inaccordance with an embodiment. FIG. 19a through FIG. 19e include ashaped abrasive particle 1900 in accordance with an embodiment. FIG. 19aincludes a perspective view of the shaped abrasive particle 1900. FIG.19b includes a front plan view of the shaped abrasive particle 1900. Theback plan view of the shaped abrasive particle 1900 is the same as thefront plan view. FIG. 19c includes a side plan view of the shapedabrasive particle 1900. Both sides of the shaped abrasive particle 1900are the same in plan view. FIG. 19d includes a top plan view of theshaped abrasive particle 1900. The bottom plan view of the shapedabrasive particle 1900 is the same as the top plan view.

As illustrated, the shaped abrasive particle 1900 is generallyrake-shaped and includes a body 1902 having a central region 1904. Afirst group of castellated projections 1906 can extend from the centralregion 1904 of the body 1902 in a first direction. A second group ofcastellated projections 1908 can extend from the central region 1904 ofthe body 1902 in a second direction. In a particular aspect, the firstgroup of castellated projections 1906 can have a length, LP1, and thesecond group of castellated projections 1908 can have a length, LP2. Aratio of LP1 to LP2 (LP1:LP2) can be at least 1:1, such as at least1.5:1, or 2:1. In another aspect, LP1:LP2 may be no greater than 5:1,such as no greater than 4:1, or no greater than 3:1.

It can be appreciated that when used to form a coated abrasive article,the second group of castellated projections 1908 can extend into andadhere to a make coat that is disposed on a backing material. The firstgroup of castellated projections 1906 can provide a plurality ofgrinding points for material removal during an abrasive operation. In aparticular aspect, the shaped abrasive particle 1900 can be formed usingone or more of the systems and methods, described herein.

FIG. 20a through FIG. 20f include a shaped abrasive particle 2000 inaccordance with an embodiment. FIG. 20a includes a perspective view ofthe shaped abrasive particle 2000. FIG. 20b includes a front plan viewof the shaped abrasive particle 2000. The back plan view of the shapedabrasive particle 2000 is the same as the front plan view. FIG. 20cincludes a first side plan view of the shaped abrasive particle 2000.FIG. 20d includes a second side plan view of the shaped abrasiveparticle 2000. FIG. 20e includes a top plan view of the shaped abrasiveparticle 2000 and FIG. 20f includes a bottom plan view of the shapedabrasive particle 2000.

As illustrated, the shaped abrasive particle 2000 includes a body 2002having a first surface 2004 and a second surface 2006. Moreover, thebody 2002 includes a side surface 2008 extending between the firstsurface 2004 and the second surface 2006. The side surface 2008 caninclude at least four distinct side surface portions, e.g., a first sidesurface portion 2010, a second side surface portion 2012, a third sidesurface portion 2014, and a fourth side surface portion 216. As shown,the side surface portions 2010, 2012, 2014, 2016 may be separated by atleast four exterior corners 2020, 2022, 2024, 2026.

As indicated in FIG. 20a through FIG. 20 f, at least one of the sidesurface portions 2010, 2012, 2014, 2016 can include a concave contour.Further, the shaped abrasive particle 2000 can have a curved shape inwhich the first surface 2004 includes a substantially concave curvatureand the second surface 2006 includes a substantially convex curvature.In a particular aspect, the shaped abrasive particle 2000 can be formedusing one or more of the systems and methods, described herein.

FIG. 21a through FIG. 21e include a shaped abrasive particle 2100 inaccordance with an embodiment. FIG. 21a includes a perspective view ofthe shaped abrasive particle 2100. FIG. 21 b includes a front plan viewof the shaped abrasive particle 2100. The back plan view is the same asthe front plan view. FIG. 21c includes a side plan view of the shapedabrasive particle 2100. Both side plan views are the same. FIG. 21dincludes a top plan view of the shaped abrasive particle 2100 and FIG.21e includes a bottom plan view of the shaped abrasive particle 2100.

As indicated, the shaped abrasive particle 2100 can include a body 2102that is generally toothed and includes a plurality of teeth 2104extending from one side of the body 2102. As shown, the teeth 2014 maydefine external corners of the body 2102 and can include an averagespacing 2106 between adjacent teeth 2104 of less than 0.5L, where Ldefines the length 2108 of the body. In another aspect, each of theteeth 2104 can include a tooth height and at least some of the teeth2104 have a different height when compared to other teeth 2104 of theplurality of teeth 2104. In yet another aspect, each of the teeth 2104can have the same height. Further, in another aspect, the body 2102 caninclude a peripheral surface and all of the teeth 2104 can be uniformlydistributed around the peripheral surface. In another aspect, the teethmay be non-uniformly distributed around the peripheral surface of thebody 2102. In another aspect, each of the teeth of the plurality ofteeth 2104 defines a single point on the body 2102. In another aspect,each of the teeth of the plurality of teeth 2104 defines multiple pointson the body 2102. In a particular aspect, the shaped abrasive particle2100 can be formed using one or more of the systems and methods,described herein.

FIG. 22a through FIG. 22d include a shaped abrasive particle 2200 inaccordance with an embodiment. FIG. 22a includes a top plan view of theshaped abrasive particle 2200. FIG. 22b is a side plan view of theshaped abrasive particle 2200. The opposite side plan view is the same.FIG. 22c is a front plan of the shaped abrasive particle 2200. The backplan view is the same as the front. FIG. 22d is a bottom plan view ofthe shaped abrasive particle 2200.

As indicated, the shaped abrasive particle 2200 can include a body 2202having a first surface 2204 and a base 2206 spaced a distance from thefirst surface 2204. A plurality of structures 2208 can extend betweenthe base 2206 and the first surface 2204 in an outward direction from acenter 2210 of the body 2202. Each of the plurality of structures 2208can include an isosceles triangle and each of the plurality ofstructures 2208 can be attached in the central region of the body 2202.Further, the body 2202 can include a bore 2212 that can extend along alength of the body 2202 and through the center 2210 of the body 2202. Ina particular aspect, the shaped abrasive particle 2200 can be formedusing one or more of the systems and methods, described herein.

FIG. 23a through FIG. 23f include a shaped abrasive particle 2300 inaccordance with an embodiment. FIG. 23a is a perspective view of theshaped abrasive particle 2300. FIG. 23b is a front plan view of theshaped abrasive particle 2300. The back plan view is the same as thefront—only in reverse. FIG. 23c is a top plan view of the shapedabrasive particle 2300. FIG. 23d is a bottom plan view of the shapedabrasive particle 2300. FIG. 23e is a first side plan view of the shapedabrasive particle 2300 and FIG. 23f is a second side plan view of theshaped abrasive particle 2300.

As illustrated, the shaped abrasive particle 2300 can include a body2302 having a first surface 2304 and a second surface 2306. A sidesurface 2308 can extend between the first surface 2304 and the secondsurface 2306. The side surface 2308 can include a first side surfaceportion 2310, a second side surface portion 2312, a third side surfaceportion 2314, and a fourth side surface portion 2316. In particular, thefirst surface 2304 of the body 2302 is concave and the first sidesurface portion 2310 can extend to the first surface 2304 to form aflashing 2318 on the body 2302 of the shaped abrasive particle 2300. Theflashing 2318 can have a flashing length, LF, and the body 2302 caninclude a length, L. A ratio of the length of the body 2302 to theflashing length, L:LF, can be at least 10:1 such as at least 9:1, atleast 8:1, at least 7:1, or at least 6:1. Further, the L:LF may be nogreater than 2:1, no greater than 3:1, or no greater than 4:1. Theincrease length of the flashing 2318 can extend the useful life of theshaped abrasive grain 2300 and a coated abrasive article, such as anabrasive belt, on which the shaped abrasive grain 2300 is deposited. Ina particular aspect, the shaped abrasive particle 2300 can be formedusing one or more of the systems and methods, described herein.

FIG. 24a through FIG. 24f include a shaped abrasive particle 2400 inaccordance with an embodiment. FIG. 24a is a perspective view of theshaped abrasive particle 2400. FIG. 24b is a top plan view of the shapedabrasive particle 2400. FIG. 24c is a bottom plan view of the shapedabrasive particle 2400. FIG. 24d is a front plan view of the shapedabrasive particle 2400. FIG. 24e is a top plan view of the shapedabrasive particle 2400 and FIG. 24f is a side plan view of the shapedabrasive particle 2400. Both side plan views are the same.

The shaped abrasive particle 2400 includes a body 2402 having a firstsurface 2404, a second surface 2406, and a third surface 2408 that areconnected to each other to form a pyramid shape with a hollow interior2410. In a particular aspect, the shaped abrasive particle 2400 can beformed using one or more of the systems and methods, described herein.

FIG. 25a through FIG. 25b include a shaped abrasive particle 2500 inaccordance with an embodiment. FIG. 25a is a top plan view of the shapedabrasive particle 2500. The bottom plan view is the same. FIG. 25b is aside plan view of the shaped abrasive particle 2500. Both side planviews, the front plan view, and the rear plan view of the shapedabrasive particle 2500 are the same.

As indicated, the shaped abrasive particle 2500 can include a body 2502having a plurality of structures 2504 equally spaced around a center2506 of the body 2502. Each of the plurality of structures 2504 caninclude an isosceles triangle shape and each of the plurality ofstructures 2504 can be attached, or otherwise bonded, to adjacentstructures 2504 to form an opening 2506, or hole that extends along alength of the body 2502 through the center 2510 of the body 2502. In aparticular aspect, the shaped abrasive particle 2500 can be formed usingone or more of the systems and methods, described herein.

FIG. 26a through FIG. 26c include a shaped abrasive particle 2600 inaccordance with an embodiment. FIG. 26a is a perspective view of theshaped abrasive particle 2600. FIG. 26b is a front plan view of theshaped abrasive particle 2600. The back plan view is the same. FIG. 26cis a side plan view of the shaped abrasive particle 2600. Both side planviews, the top plan view, and the bottom plan view are the same. Mentionthat the arms on these stars are thicker at the base.

As illustrated, the shaped abrasive particle 2600 can include a body2602. The body 2602 can be generally star shaped and flat. Moreover, thebody 2602 can include a first point 2604, a second point 2606, a thirdpoint 2608, and a fourth point 2610. The points 2604, 2606, 2608, 2610can be equally spaced around a center 2612 of the body 2602. In aparticular aspect, the shaped abrasive particle 2600 can be formed usingone or more of the systems and methods, described herein.

FIG. 27a through FIG. 27c include a shaped abrasive particle 2700 inaccordance with an embodiment. FIG. 27a is a perspective view of theshaped abrasive particle 2700. FIG. 27b is a front plan view of theshaped abrasive particle 2700. The back plan view is the same. FIG. 27cis a side plan view of the shaped abrasive particle 2700. Both side planviews, the top plan view, and the bottom plan view are the same.

As illustrated, the shaped abrasive particle 2700 can include a body2702. The body 2702 can be generally star shaped. Moreover, the body2702 can include a first point 2704, a second point 2706, a third point2708, and a fourth point 2710. The points 2704, 2706, 2708, 2710 can beequally spaced around a center 2712 of the body 2702. Moreover, the body2702 of the shaped abrasive particle 2700 can have a thickness 2720 thatincreases from each point 2704, 2706, 2708, 2710 to the center 2712 ofthe body 2702. Further, the body 2702 can include a first central point2722 and a second central point 2724 opposite the first central point2722. In a particular aspect, the shaped abrasive particle 2700 can beformed using one or more of the systems and methods, described herein.

FIG. 28a through FIG. 28e include a shaped abrasive particle 2800 inaccordance with an embodiment. FIG. 28a includes a perspective view ofthe shaped abrasive particle 2800. FIG. 28b includes a front plan viewof the shaped abrasive particle 2800. FIG. 28c includes a back plan viewof the shaped abrasive particle 2800. FIG. 28d is a bottom plan view ofthe shaped abrasive particle 2800. The top plan view is the same as thebottom. FIG. 28e is a side plan view of the shaped abrasive particle2800. Both side plan views are the same.

As illustrated, the shaped abrasive particle 2800 can include a body2802 having a first triangular portion 2804 and a second triangularportion 2806. The triangular portions 2804, 2806 can be bonded, orotherwise fused, to each other along a central axis 2808. In particular,the triangular portions 2804, 2806 can be bonded to each other so that aside surface 2810 formed after bonding the triangular portions 2804,2806 together includes an angle 2812.

The angle 2812 of the side surface 2810 can be less than or equal to180°, such as less than or equal to 170°, less than or equal to 160°,less than or equal to 150°, less than or equal to 140°, or less than orequal to 130°. In another aspect, the angle 2812 of the side surface canbe greater than or equal to 90°, such as greater than or equal to 100°,greater than or equal to 110°, or greater than or equal to 120°.

In another aspect, the triangular portions 2804, 2806 can be shaped sothat a first surface 2814 formed when the triangular portions 2804, 2806are bonded together also includes an angle 2816. The angle 2816 of thefirst surface 2814 can be less than or equal to 180°, such as less thanor equal to 170°, less than or equal to 160°, less than or equal to150°, less than or equal to 140°, or less than or equal to 130°. Inanother aspect, the angle 2816 of the first surface 2814 can be greaterthan or equal to 90°, such as greater than or equal to 100°, greaterthan or equal to 110°, or greater than or equal to 120°. In a particularaspect, the shaped abrasive particle 2800 can be formed using one ormore of the systems and methods, described herein.

In another aspect, the triangular portions 2804, 2806 of the body 2802of the shaped abrasive particle 2800 can be considered flanges and asshown, the flanges can extend in different planes with respect to eachother at one or more of the angles described.

FIG. 29a through FIG. 29c include a shaped abrasive particle 2900 inaccordance with an embodiment. FIG. 29a is a top plan view of the shapedabrasive particle 2900. The bottom plan view is the same as the top planview. FIG. 29b is a side plan view of the shaped abrasive particle 2900.Both side plan views, the front plan view, and the rear plan view of theshaped abrasive particle 2900 are the same. FIG. 29c is a crosssectional view of the shaped abrasive particle 2900.

As illustrated, the shaped abrasive particle 2900 includes a body 2902.The body 2902 is toroid shaped, or annular, and includes thecross-sectional shape depicted in FIG. 29 c. In particular, the body2902 of shaped abrasive particle 2900 includes a first major surface2904 and a second major surface 2906. A first side surface 2908 canextend between the first major surface 2904 and the second major surface2906. As depicted in FIG. 29 c, the first side surface 2908 is linear incross-section. The body 2902 can also include a second side surface 2910that can extend between the first major surface 2904 and the secondmajor surface 2906. As shown in FIG. 29 c, the second side surface 2910is concave in cross-section. In a particular aspect, the shaped abrasiveparticle 2900 can be formed using one or more of the systems andmethods, described herein.

FIG. 30a through FIG. 30d include a shaped abrasive particle 3000 inaccordance with an embodiment. FIG. 30a is a top plan view of the shapedabrasive particle 3000. FIG. 30b is a bottom plan view of the shapedabrasive particle 3000. FIG. 30b is a side plan view of the shapedabrasive particle 3000. Both side plan views, the front plan view, andthe rear plan view of the shaped abrasive particle 3000 are the same.FIG. 30c is a cross sectional view of the shaped abrasive particle 3000.

As illustrated, the shaped abrasive particle 3000 includes a body 3002.The body 3002 is toroid shaped and includes the cross-sectional shapedepicted in FIG. 30 c. In particular, the body 3002 of shaped abrasiveparticle 3000 includes a first major surface 3004 and a second majorsurface 3006. A first side surface 3008 can extend between the firstmajor surface 3004 and the second major surface 3006. As depicted inFIG. 30 c, the first side surface 3008 is linear in cross-section. Thebody 3002 can also include a second side surface 3010 that can extendbetween the first major surface 3004 and the second major surface 3006.As shown in FIG. 30c , the second side surface 3008 is linear incross-section and can form an angle 3012 with respect to the secondmajor surface 3004.

The angle 3012 can be greater than or equal to 45°, such as greater thanor equal 50°, greater than or equal 55°, or greater than or equal 60°.Further, the angle 3012 can be less than or equal to 85°, such as lessthan or equal to 80°, less than or equal to 75°, less than or equal to70°, or less than or equal to 65°. In a particular aspect, the shapedabrasive particle 3000 can be formed using one or more of the systemsand methods, described herein.

FIG. 31a through FIG. 31c include a shaped abrasive particle inaccordance with an embodiment. FIG. 31a is a top plan view of the shapedabrasive particle 3100. The bottom plan view is the same as the top planview. FIG. 31b is a side plan view of the shaped abrasive particle 3100.Both side plan views, the front plan view, and the rear plan view of theshaped abrasive particle 3100 are the same. FIG. 31c is a crosssectional view of the shaped abrasive particle 3100.

As illustrated, the shaped abrasive particle 3100 includes a body 3102.The body 3102 is toroid shaped and includes the cross-sectional shapedepicted in FIG. 31 c. In particular, the body 3102 of shaped abrasiveparticle 3100 includes a first major surface 3104 and a second majorsurface 3106. A first side surface 3108 can extend between the firstmajor surface 3104 and the second major surface 3106. As depicted inFIG. 31 c, the first side surface 3108 is linear in cross-section. Thebody 3102 can also include a second side surface 3110 that can extendbetween the first major surface 3104 and the second major surface 3106.As shown in FIG. 31c , the second side surface 3108 is can include afirst portion 3112 and a second portion 3114. The first portion 3112 ofthe second side surface 3110 can form an angle 3116 with respect to thesecond portion 3114 of the second side surface 3110.

The angle 3116 can be greater than or equal to 90°, such as greater thanor equal 100°, greater than or equal 110°, or greater than or equal120°. Further, the angle 3116 can be less than or equal to 170°, such asless than or equal to 160°, less than or equal to 150°, less than orequal to 140°, or less than or equal to 130°. In a particular aspect,the shaped abrasive particle 3100 can be formed using one or more of thesystems and methods, described herein.

FIG. 32a through FIG. 32c include a shaped abrasive particle inaccordance with an embodiment. FIG. 32a is a top plan view of the shapedabrasive particle 3200. The bottom plan view is the same as the top planview. FIG. 32b is a side plan view of the shaped abrasive particle 3200.Both side plan views, the front plan view, and the rear plan view of theshaped abrasive particle 3200 are the same. FIG. 32c is a crosssectional view of the shaped abrasive particle 3200.

As illustrated, the shaped abrasive particle 3200 includes a body 3202.The body 3202 is toroid shaped and includes the cross-sectional shapedepicted in FIG. 32 c. In particular, the body 3202 of shaped abrasiveparticle 3200 includes a first major surface 3204 and a second majorsurface 3206. A first side surface 3208 can extend between the firstmajor surface 3204 and the second major surface 3206. As depicted inFIG. 32 c, the first side surface 3208 is concave in cross-section. Thebody 3202 can also include a second side surface 3210 that can extendbetween the first major surface 3204 and the second major surface 3206.As shown in FIG. 32c , the second side surface 3210 is concave incross-section. It can be appreciated that either the first side surface3208, the second side surface 3210, or both side surfaces 3208, 3210 canbe convex is cross-section. In a particular aspect, the shaped abrasiveparticle 3200 can be formed using one or more of the systems andmethods, described herein.

FIG. 33a through FIG. 33d include a shaped abrasive particle inaccordance with an embodiment. FIG. 33a is a top plan view of the shapedabrasive particle 3300. FIG. 33b is a bottom plan view of the shapedabrasive particle 3300. FIG. 33b is a side plan view of the shapedabrasive particle 3300. Both side plan views, the front plan view, andthe rear plan view of the shaped abrasive particle 3300 are the same.FIG. 33c is a cross sectional view of the shaped abrasive particle 3300.

As illustrated, the shaped abrasive particle 3300 includes a body 3302.The body 3302 is toroid shaped, or annular with a central openingextending through the body 3302 and a rounded contour, and includes thecross-sectional shape depicted in FIG. 33 c. In particular, the body3302 of shaped abrasive particle 3300 includes a first major surface3304 and a second major surface 3306. As shown in FIG. 33 d, incross-section, the first major surface 3304 is not parallel to thesecond major surface 3306. Also, the first major surface 3304 is linearin cross-section. However, it can be appreciated that the first majorsurface 3304 can be concave, rounded, or otherwise non-planar, incross-section.

As illustrated, a first side surface 3308 can extend between the firstmajor surface 3304 and the second major surface 3306. As depicted inFIG. 33 c, the first side surface 3308 is linear in cross-section. Thefirst major surface 3304 can form an angle 3310 with respect to thefirst side surface 3308.

In a particular aspect, the angle 3310 can be greater than or equal to95°, such as greater than or equal 100°, greater than or equal 105°, orgreater than or equal 110°. Further, the angle 3310 can be less than orequal to 150°, such as less than or equal to 140°, less than or equal to130°, or less than or equal to 120°. The body 3302 can also include asecond side surface 3312 that can extend between the first major surface3304 and the second major surface 3306. As shown in FIG. 33 c, thesecond side surface 3312 is concave in cross-section. In a particularaspect, the shaped abrasive particle 3300 can be formed using one ormore of the systems and methods, described herein.

FIG. 34a through FIG. 34e include a shaped abrasive particle 3400 inaccordance with an embodiment. FIG. 34a is a perspective view of theshaped abrasive particle 3400. FIG. 34b is a front plan view of theshaped abrasive particle 3400. The back plan view is the same as thefront plan view. FIG. 34c is a top plan view of the shaped abrasiveparticle 3400. The bottom plan view of the shaped abrasive particle 3400is the same as the top plan view. FIG. 34d is a side plan view of theshaped abrasive particle 3400. Both side plan views of the shapedabrasive particle 3400 are the same.

As illustrated, the shaped abrasive particle 3400 can include a body3402 having a first triangular portion 3404 and a second triangularportion 3406. The triangular portions 3404, 3406 can be bonded, orotherwise fused, to each other along a side surface 3408, 3410 of eachtriangular portion 3404, 3406. In particular, the triangular portions3404, 3406 can be bonded to each other so that in the side plan view ofFIG. 34 b, a first surface 3412 of the first triangular portion 3404 canform an angle 3414 with respect to a first surface 3416 of the secondtriangular portion 3406.

The angle 3414 can be less than or equal to 120°, such as less than orequal to 110°, less than or equal to 100°, or less than or equal to 90°.In another aspect, the angle 3414 of can be greater than or equal to50°, such as greater than or equal to 60°, greater than or equal to 70°,or greater than or equal to 80°. In another aspect, the first triangularportion 3404 can include a second surface 3418 and the second triangularportion 3406 can include a second surface 3420. When the triangularportions 3404, 3406 are bonded together, as depicted, the second surface3418 of the first triangular portion 3404 can be coplanar with thesecond surface 3420 of the second triangular portion 3406, e.g., to forma base for the shaped abrasive particle 3400. In a particular aspect,the shaped abrasive particle 3400 can be formed using one or more of thesystems and methods, described herein.

FIG. 35a through FIG. 35e include a shaped abrasive particle 3500 inaccordance with an embodiment. FIG. 35a includes a perspective view ofthe shaped abrasive particle 3500. FIG. 35b includes a front plan viewof the shaped abrasive particle 3500. The back plan view is the same asthe front plan view. FIG. 35c is a side plan view of the shaped abrasiveparticle 3500. Both side plan views are the same. FIG. 35d is a top planview of the shaped abrasive particle 3500 and FIG. 35e is a bottom planview of the shaped abrasive particle 3500.

As illustrated, the shaped abrasive particle 3500 can include a body3502 having a first triangular portion 3504 and a second triangularportion 3506. The triangular portions 3504, 3506 can be bonded, orotherwise fused, to each other along a side surface 3508, 3510 of eachtriangular portion 3504, 3506. In particular, the triangular portions3504, 3506 can be equilateral triangles and the triangular portions3504, 3506 can be bonded to each other so that in the side plan view ofFIG. 35 b, the shaped abrasive particle 3500 can be shaped like asix-point star. In a particular aspect, the shaped abrasive particle3500 can be formed using one or more of the systems and methods,described herein.

FIG. 36a through FIG. 36e include a twenty-seventh shaped abrasiveparticle 3900 in accordance with an embodiment. FIG. 36a is aperspective view of the twenty-seventh shaped abrasive particle 3900.FIG. 36b is a front plan view of the twenty-seventh shaped abrasiveparticle 3900. The back plan view is the same as the front plan view.FIG. 36c is a top plan view of the twenty-seventh shaped abrasiveparticle 3900. FIG. 36d is a bottom plan view of the twenty-seventhshaped abrasive particle 3900. FIG. 36e is a side plan view of thetwenty-seventh shaped abrasive particle 3900. Both side plan views ofthe twenty-seventh shaped abrasive particle 3900 are the same.

The shaped abrasive particle 3900 can include a body 3902 that can beformed by creating a layer of material from a mixture comprising aprecursor ceramic material. The body 3902 can include a pattern 3904formed in an upper surface 3906 of the body 3902. The pattern 3904 canbe formed by altering the upper surface 3906 of the body 3902 byexposing it to a gaseous or liquid material in order to create thepattern 3904 in the upper surface 3906 of the body 3902, e.g., the layerof material that forms the body 3902. In a particular aspect, the shapedabrasive particle 3900 can be formed into a plurality of abrasiveparticles, e.g., by crushing the shaped abrasive particle 3900. In sucha case, at least a portion of the abrasive particles formed from theshaped abrasive particle 3900 can include a surface having at least aportion of the pattern created in the upper surface 3906 of the layermaking up the body 3902. In a particular aspect, the shaped abrasiveparticle 3900 can be formed using one or more of the systems andmethods, described herein. In particular, the shaped abrasive particle3900 can be formed by first forming a sheet of gel and then, agitatingsurface of the sheet of gel, e.g., using air driven by a fan blade orimpeller, before the gel is dried in order to create waves or ripplefeatures in the upper surface of the sheet of gel to achieve the patternshown in the abrasive particle 3900.

FIG. 37a through FIG. 37e include a shaped abrasive particle 4000 inaccordance with an embodiment. FIG. 37a through FIG. 37e include ashaped abrasive particle 4000 in accordance with an embodiment. FIG. 37ais a perspective view of the shaped abrasive particle 4000. FIG. 37b isa front plan view of the shaped abrasive particle 4000. The back planview is the same as the front plan view. FIG. 37c is a top plan view ofthe shaped abrasive particle 4000. FIG. 37d is a bottom plan view of theshaped abrasive particle 4000. FIG. 37e is a side plan view of theshaped abrasive particle 4000. Both side plan views of the shapedabrasive particle 4000 are the same.

The shaped abrasive particle 4000 can include a body 4002 that can beformed by creating a layer of material from a mixture comprising aprecursor ceramic material. The body 4002 can include a pattern 4004formed in an upper surface 4006 of the body 4002. The pattern 4004 canbe formed by altering the upper surface 4006 of the body 4002 byexposing it to a gaseous or liquid material in order to create thepattern 4004 in the upper surface 4006 of the body 4002, e.g., the layerof material that forms the body 4002. In a particular aspect, the shapedabrasive particle 4000 can be formed into a plurality of abrasiveparticles, e.g., by crushing the shaped abrasive particle 4000. In sucha case, at least a portion of the abrasive particles formed from theshaped abrasive particle 4000 can include a surface having at least aportion of the pattern created in the upper surface 4006 of the layermaking up the body 4002. In a particular aspect, the shaped abrasiveparticle 4000 can be formed using one or more of the systems andmethods, described herein. In particular, the shaped abrasive particle4000 can be formed by first forming a sheet of gel and then, agitatingsurface of the sheet of gel, e.g., using air driven by a fan blade orimpeller, before the gel is dried in order to create waves or ripplefeatures in the upper surface of the sheet of gel to achieve the patternshown in the abrasive particle 4000.

FIG. 38a through FIG. 38f include a shaped abrasive particle 4100 inaccordance with an embodiment. FIG. 38a is a perspective view of theshaped abrasive particle 4100. FIG. 38b is a front plan view of theshaped abrasive particle 4100. The back plan view is the same as thefront. FIG. 38c is a top plan view of the shaped abrasive particle 4100.FIG. 38d is a bottom plan view of the shaped abrasive particle 4100.FIG. 38e is a first side plan view of the shaped abrasive particle 4100and FIG. 38f is a second side plan view of the shaped abrasive particle4100. In a particular aspect, the shaped abrasive particle 4100 can beformed using a screen printing process and overfilling the screen in onedirection as described herein.

As depicted, the shaped abrasive particle 4100 can include a body 4102having a first surface 4104 and a second surface 4106. A side surface4108 can extend between the first surface 4104 and the second surface4106. The body 4102 can also include a flange 4110 that can extend fromthe side surface 4108 and the first surface 4104. In a particularaspect, the flange 4110 can include a rounded shape. Further, the flange4110 can include a flange length 4112. The flange length 4112 can beless than a length 4114 of the body 4102. In another aspect, the flange4110 can include a height 4116 and the height 4116 of the flange 4110 isnot greater than a thickness 4118 of the body 4102. In another aspect,the body 4102 can only include a single flange 4110 and the flange 4110extends along the periphery of the body 4102 for a distance that is notgreater than 50% of the total peripheral length of the body 4102. Inparticular, the flange can extend around at least one exterior corner ofthe body 4102 and not greater than three exterior corners.

The body 4102 can include a narrow end 4120 and wide end 4122. Theflange 4110 can extend from the narrow end 4120 of the body 4102. In aparticular aspect, the shaped abrasive particle 4100 can be formed usingone or more of the systems and methods, described herein.

FIG. 39a through FIG. 39f include a shaped abrasive particle 4200 inaccordance with an embodiment. FIG. 39a is a perspective view of theshaped abrasive particle 4200. FIG. 39b is a front plan view of theshaped abrasive particle 4200. The back plan view is the same as thefront. FIG. 39c is a top plan view of the shaped abrasive particle 4200.FIG. 39d is a bottom plan view of the shaped abrasive particle 4200.FIG. 39e is a first side plan view of the shaped abrasive particle 4200and FIG. 39f is a second side plan view of the shaped abrasive particle4200. In a particular aspect, the shaped abrasive particle 4200 can beformed using a screen printing process and overfilling the screen in onedirection as described herein.

As depicted, the shaped abrasive particle 4200 can include a body 4202having a first surface 4204 and a second surface 4206. A side surface4208 can extend between the first surface 4204 and the second surface4206. The body 4202 can also include a flange 4210 that can extend fromthe side surface 4208 and the first surface 4204. In a particularaspect, the flange 4210 can include a rounded shape. Further, the flange4210 can include a flange length 4212. The flange length 4212 can beless than a length 4214 of the body 4202. In another aspect, the flange4210 can include a height 4216 and the height 4216 of the flange 4210 isnot greater than a thickness 4218 of the body 4202. In another aspect,the body 4202 can only include a single flange 4210 and the flange 4210extends along the periphery of the body 4202 for a distance that is notgreater than 50% of the total peripheral length of the body 4202. Inparticular, the flange can extend around at least one exterior corner ofthe body 4202 and not greater than three exterior corners.

The body 4202 can include a narrow end 4220 and wide end 4222. Theflange 4210 can extend from the wide end 4220 of the body 4202. In aparticular aspect, the shaped abrasive particle 4200 can be formed usingone or more of the systems and methods, described herein.

FIG. 40a through FIG. 40c include a shaped abrasive particle 4300 inaccordance with an embodiment. FIG. 40a is a perspective view of theshaped abrasive particle 4300. FIG. 40b is a front plan view of theshaped abrasive particle 4300. The back plan view is the same as thefront plan view. FIG. 40c is a side plan view of the shaped abrasiveparticle 4300. Both side plan views, the top plan view, and the bottomplan view of the shaped abrasive particle 4300 are the same.

As indicated, the shaped abrasive particle 4300 can include a body 4302having a peripheral surface 4304. A plurality of teeth 4306 can extendfrom the peripheral surface 4304 of the body 4302. As shown, theplurality of teeth 4306 do not extend to the corners 4308, 4310, 4312,4314 of the body 4308. Further, each of the teeth 4304 can have the sameheight and all of the teeth 4304 can be uniformly distributed around theperipheral surface 4304 of the body. In a particular aspect, the shapedabrasive particle 4300 can be formed using one or more of the systemsand methods, described herein.

FIG. 41a through FIG. 41c include a shaped abrasive particle 4400 inaccordance with an embodiment. FIG. 41a is a perspective view of theshaped abrasive particle 4400. FIG. 41b is a front plan view of theshaped abrasive particle 4400. The back plan view is the same as thefront plan view. FIG. 41c is a side plan view of the shaped abrasiveparticle 4400. Both side plan views, the top plan view, and the bottomplan view of the shaped abrasive particle 4400 are the same.

As indicated, the shaped abrasive particle 4400 can include a body 4402having a peripheral surface 4404. A plurality of teeth 4406 can extendfrom the peripheral surface 4404 of the body 4402. As shown, theplurality of teeth 4406 extend to, and form, the corners 4408, 4410,4412, 4414 of the body 4408. Further, each of the teeth 4404 can havethe same height and all of the teeth 4404 can be uniformly distributedaround the peripheral surface 4404 of the body. In a particular aspect,the shaped abrasive particle 4400 can be formed using one or more of thesystems and methods, described herein.

FIG. 42a through FIG. 42c include a shaped abrasive particle 4500 inaccordance with an embodiment. FIG. 42a is a perspective view of theshaped abrasive particle 4500. FIG. 42b is a front plan view of theshaped abrasive particle 4500. The back plan view is the same as thefront plan view. FIG. 42c is a side plan view of the shaped abrasiveparticle 4500. Both side plan views, the top plan view, and the bottomplan view of the shaped abrasive particle 4500 are the same.

As indicated, the shaped abrasive particle 4500 can include a body 4502having a peripheral surface 4504. A plurality of teeth 4506 can extendfrom the peripheral surface 4504 of the body 4502. As shown, theplurality of teeth 4506 extend to, and form, the corners 4508, 4510,4512, 4514 of the body 4508. Further, each of the teeth 4504 can havedifferent heights when compared to other teeth and the teeth 4504 ofvarying sizes can be uniformly distributed around the peripheral surface4504 of the body. In a particular aspect, the shaped abrasive particle4500 can be formed using one or more of the systems and methods,described herein.

FIG. 43a through FIG. 43d include a shaped abrasive particle 4600 inaccordance with an embodiment. FIG. 43a is a perspective view of theshaped abrasive particle 4600. FIG. 43b is a front plan view of theshaped abrasive particle 4600. The back plan view of the shaped abrasiveparticle 4600 is the same as the front plan view. FIG. 43c is a sideplan view of the shaped abrasive particle 4600. Both side plan views,the top plan view, and the bottom plan view of the shaped abrasiveparticle 4600 are the same. FIG. 43d is a cross-sectional view of theshaped abrasive particle 4600. In a particular aspect, the shapedabrasive particle 4600 can be formed using one or more of the systemsand methods, described herein.

As illustrated, the shaped abrasive particle 4600 can include a body4602. The body 4602 can be generally star shaped. Moreover, the body4602 can include a first point 4604, a second point 4606, a third point4608, and a fourth point 4610. The points 4604, 4606, 4608, 4610 can beequally spaced around a central portion 4612 of the body 4602. Moreover,the body 4602 of the shaped abrasive particle 4600 can have a thickness4620 that can increase from the central portion 4612 of the body 4602outwardly toward each point 4604, 4606, 4608, 4610. In a particularaspect, the shaped abrasive particle 4600 can be formed using one ormore of the systems and methods, described herein.

FIG. 44a through FIG. 44e include a shaped abrasive particle 4700 inaccordance with an embodiment. FIG. 44a is a perspective view of theshaped abrasive particle 4700. FIG. 44b is a front plan view of theshaped abrasive particle 4700. The back plan view is the same as thefront plan view. FIG. 44c is a side plan view of the shaped abrasiveparticle 4700. Both side plan views of the shaped abrasive particle 4700are the same. FIG. 44d is a top plan view of the shaped abrasiveparticle 4700 and FIG. 44e is a bottom plan view of the shaped abrasiveparticle 4700.

As illustrated, the shaped abrasive particle 4700 can include a body4702 that can be generally shaped like an arrowhead, or a shark's tooth.The body 4702 can include a first major surface 4704 and a second majorsurface 4706. A side surface 4708 can extend between the first majorsurface 4704 and the second major surface 4706. The side surface 4708can include a first portion 4710, a second portion 4712, and a thirdportion 4714. The first portion 4710 can form an angle 4714 with respectto the second portion 4712. The angle 4714 can be less than or equal to75°, such as less than or equal to 60°, less than or equal to 50°, lessthan or equal to 40°, or less than or equal to 35°. In another aspect,the angle 4714 can be greater than or equal to 15°, such as greater thanor equal to 20°, greater than or equal to 25°, or greater than or equalto 30°.

FIG. 44b shows that the third portion 4714 of the side surface 4708 canextend between the first portion 4710 and the second portion 4712 of theside surface 4708 and can be concave. Moreover, the first portion 4710of the side surface 4708 can include a serrated, or toothed, portion4718. Similarly, the second portion 4712 of the side surface 4708 caninclude a serrated, or toothed, portion 4720. In a particular aspect,the shaped abrasive particle 4700 can be formed using one or more of thesystems and methods described herein.

FIG. 45a through FIG. 45e include a shaped abrasive particle 4800 inaccordance with an embodiment. FIG. 45a is a perspective view of theshaped abrasive particle 4800. FIG. 45b is a front plan view of theshaped abrasive particle 4800. The back plan view is the same as thefront plan view. FIG. 45c is a side plan view of the shaped abrasiveparticle 4800. Both side plan views of the shaped abrasive particle 4800are the same. FIG. 45d is a top plan view of the shaped abrasiveparticle 4800 and FIG. 45e is a bottom plan view of the shaped abrasiveparticle 4800.

As illustrated, the shaped abrasive particle 4800 can include a body4802 that can be generally shaped like an arrowhead, or a shark's tooth.The body 4802 can include a first major surface 4804 and a second majorsurface 4806. A side surface 4808 can extend between the first majorsurface 4804 and the second major surface 4806. The side surface 4808can include a first portion 4810, a second portion 4812, and a thirdportion 4814. The first portion 4810 can form an angle 4814 with respectto the second portion 4812. The angle 4814 can be less than or equal to75°, such as less than or equal to 60°, less than or equal to 50°, lessthan or equal to 40°, or less than or equal to 35°. In another aspect,the angle 4814 can be greater than or equal to 15°, such as greater thanor equal to 20°, greater than or equal to 25°, or greater than or equalto 30°.

FIG. 45b shows that the third portion 4814 of the side surface 4808 canextend between the first portion 4810 and the second portion 4812 of theside surface 4808 and can be generally triangular and rounded at theapex. Moreover, the first portion 4810 of the side surface 4808 caninclude a serrated, or toothed, portion 4818. Similarly, the secondportion 4812 of the side surface 4808 can include a serrated, ortoothed, portion 4820. As indicated in FIG. 45 c, the body 4802 of theshaped abrasive particle 4800 can have a thickness 4822. The thickness4822 of the body 4802 can decrease outwardly from a central region ofthe body 4802. In a particular aspect, the shaped abrasive particle 4800can be formed using one or more of the systems and methods describedherein.

The shaped abrasive particles described herein can be formed such thateach respective body can include a crystalline material, and moreparticularly, a polycrystalline material. Notably, the polycrystallinematerial can include abrasive grains. In one embodiment, the body can beessentially free of an organic material, including for example, abinder. More particularly, the body can consist essentially of apolycrystalline material.

In one aspect, the body of each shaped abrasive particle can be anagglomerate including a plurality of abrasive particles, grit, and/orgrains bonded to each other to form the body of the abrasive particle.Suitable abrasive grains can include nitrides, oxides, carbides,borides, oxynitrides, oxyborides, diamond, and a combination thereof. Inparticular instances, the abrasive grains can include an oxide compoundor complex, such as aluminum oxide, zirconium oxide, titanium oxide,yttrium oxide, chromium oxide, strontium oxide, silicon oxide, and acombination thereof. In one particular instance, each shaped abrasiveparticle can be formed such that the abrasive grains forming the bodythereof can include alumina, and more particularly, may consistessentially of alumina. Moreover, in particular instances, the shapedabrasive particle can be formed from a seeded sol-gel.

The abrasive grains (i.e., crystallites) contained within the body mayhave an average grain size that is generally not greater than about 100microns. In other embodiments, the average grain size can be less, suchas not greater than about 80 microns, not greater than about 50 microns,not greater than about 30 microns, not greater than about 20 microns,not greater than about 10 microns, or even not greater than about 1micron, not greater than about 0.9 microns, not greater than about 0.8microns, not greater than about 0.7 microns, or even not greater thanabout 0.6 microns. Still, the average grain size of the abrasive grainscontained within each body can be at least about 0.01 microns, such asat least about 0.05 microns, at least about 0.06 microns, at least about0.07 microns, at least about 0.08 microns, at least about 0.09 microns,at least about 0.1 microns, at least about 0.12 microns, at least about0.15 microns, at least about 0.17 microns, at least about 0.2 microns,or even at least about 0.5 microns. It will be appreciated that theabrasive grains can have an average grain size within a range betweenany of the minimum and maximum values noted above.

In accordance with certain embodiments, one or more of the abrasiveparticles described herein can be a composite article including at leasttwo different types of grains within the respective body. It will beappreciated that different types of grains are grains having differentcompositions with regard to each other. For example, the body can beformed such that is includes at least two different types of grains,wherein the two different types of grains can be nitrides, oxides,carbides, borides, oxynitrides, oxyborides, diamond, and a combinationthereof.

In accordance with an embodiment, the shaped abrasive particlesdescribed herein can have an average particle size, as measured by thelargest dimension measurable on the body thereof, of at least about 100microns. In fact, the shaped abrasive particles can have an averageparticle size of at least about 150 microns, such as at least about 200microns, at least about 300 microns, at least about 400 microns, atleast about 500 microns, at least about 600 microns, at least about 700microns, at least about 800 microns, or even at least about 900 microns.Still, the shaped abrasive particles can have an average particle sizethat is not greater than about 5 mm, such as not greater than about 3mm, not greater than about 2 mm, or even not greater than about 1.5 mm.It will be appreciated that the abrasive particle 300 can have anaverage particle size within a range between any of the minimum andmaximum values noted above.

The shaped abrasive particles of the embodiments herein, e.g., thebodies thereof, can have particular compositions. For example, thebodies may include a ceramic material, such as a polycrystalline ceramicmaterial, and more particularly an oxide. The oxide may include, forexample alumina. In certain instances, the bodies may include a majoritycontent of alumina, such as at least about 95 wt % alumina for the totalweight of the body, or such as at least about 95.1 wt %, at least about95.2 wt %, at least about 95.3 wt %, at least about 95.4 wt %, at leastabout 95.5 wt %, at least about 95.6 wt %, at least about 95.7 wt %, atleast about 95.8 wt %, at least about 95.9 wt %, at least about 96 wt %,at least about 96.1 wt %, at least about 96.2 wt %, at least about 96.3wt %, at least about 96.4 wt %, at least about 96.5 wt %, at least about96.6 wt %, at least about 96.7 wt %, at least about 96.8 wt %, at leastabout 96.9 wt %, at least about 97 wt %, at least about 97.1 wt %, atleast about 97.2 wt %, at least about 975.3 wt %, at least about 97.4 wt%, or even at least about 97.5 wt % alumina for the total weight of thebody. Still, in another non-limiting embodiment, the bodies may includea content of alumina not greater than about 99.5 wt %, such as notgreater than about 99.4 wt %, not greater than about 99.3wt %, notgreater than about 99.2 wt %, not greater than about 99.1 wt %, notgreater than about 99 wt %, not greater than about 98.9 wt %, notgreater than about 98.8 wt %, not greater than about 98.7wt %, notgreater than about 98.6 wt %, not greater than about 98.5 wt %, notgreater than about 98.4 wt %, not greater than about 98.3 wt %, notgreater than about 98.2 wt %, not greater than about 98.1wt %, notgreater than about 98 wt %, not greater than about 97.9 wt %, notgreater than about 97.8 wt %, not greater than about 97.7 wt %, notgreater than about 97.6 wt %, or even not greater than about 97.5wt %alumina for the total weight of the body 1201. It will be appreciatedthat the bodies may include a content of alumina within a range betweenany of the minimum and maximum values noted above.

The bodies of the shaped abrasive particles maybe formed to includecertain additives. The additives can be non-organic species, includingbut not limited to an oxide. In one particular instance, the additivemay be a dopant material, which may be present in a particular minoramount sufficient to affect the microstructure of the material, butpresent in a greater content than a trace amount or less. The dopantmaterial may include an element selected from the group of hafnium,zirconium, niobium, tantalum, molybdenum, vanadium, lithium, sodium,potassium, magnesium, calcium, strontium, barium, scandium, yttrium,lanthanum, cesium, praseodymium, chromium, cobalt, iron, germanium,manganese, nickel, titanium, zinc, and a combination thereof. In still amore particular embodiment, the dopant material may include magnesium,and may be a magnesium-containing species, including but not limited to,magnesium oxide (MgO).

According to one embodiment, the magnesium-containing species can be acompound including magnesium and at least one other element. In at leastone embodiment, the magnesium-containing compound can include an oxidecompound, such that the magnesium-containing species includes magnesiumand oxygen. In yet another embodiment, the magnesium-containing speciescan include aluminum, and more particularly may be a magnesium aluminatespecies. For example, in certain instances, the magnesium-containingspecies can be a spinel material. The spinel material may bestoichiometric or non-stoichiometric spinel.

The magnesium-containing species may be a distinct phase of materialformed in the body as compared to another primary phase, including forexample, an alumina phase. The magnesium-containing species may bepreferentially disposed at the grain boundaries of the primary phase(e.g., alumina grains). In still other instances, themagnesium-containing species may be primarily and uniformly dispersedthroughout the volume of the grains of the primary phase.

The magnesium-containing species may be a strength-altering material.For example, in at least one embodiment, the addition of themagnesium-containing species can be configured to reduce the strength ofthe body compared to a body that does not include themagnesium-containing species.

Certain compositions of the shaped abrasive particles of the embodimentscan include a particular content of magnesium oxide. For example, thebodies of any of the shaped abrasive particles may include a content ofa magnesium-containing species of at least about 0.5 wt %, such as atleast about 0.6 wt %, at least about 0.7 wt %, at least about 0.8 wt %,at least about 0.9 wt %, at least about 1 wt %, at least about 1.1 wt %,at least about 1.2 wt %, at least about 1.3 wt %, at least about 1.4 wt%, at least about 1.5 wt %, at least about 1.6 wt %, at least about 1.7wt %, at least about 1.8 wt %, at least about 1.9 wt %, at least about 2wt %, at least about 2.1 wt %, at least about 2.2 wt %, at least about2.3 wt %, at least about 2.4 wt %, or even at least about 2.5 wt % forthe total weight of the body 1201. In still another non-limitingembodiment, the body 1201 may include a content of amagnesium-containing species of not greater than about 5 wt %, such asnot greater than about 4.9 wt %, not greater than about 4.8 wt %, notgreater than about 4.7wt %, not greater than about 4.6 wt %, not greaterthan about 4.5 wt %, not greater than about 4.4 wt %, not greater thanabout 4.3 wt %, not greater than about 4.2wt %, not greater than about4.1 wt %, not greater than about 4 wt %, not greater than about 3.9 wt%, not greater than about 3.8 wt %, not greater than about 3.7wt %, notgreater than about 3.6 wt %, not greater than about 3.5 wt %, notgreater than about 3.4 wt %, not greater than about 3.3 wt %, notgreater than about 3.2wt %, not greater than about 3.1 wt %, not greaterthan about 3 wt %, not greater than about 2.9 wt %, not greater thanabout 2.8 wt %, not greater than about 2.7wt %, not greater than about2.6 wt %, or even not greater than about 2.5 wt %. It will beappreciated that the content of a magnesium-containing species withinthe bodies may be within a range between any of the minimum and maximumvalues noted above. Furthermore, in at least one embodiment, the bodiesof the shaped abrasive particles may consist essentially of alumina(Al₂O₃) and the magnesium-containing species.

Moreover, the bodies of the shaped abrasive particle of any of theembodiments herein may be formed of a polycrystalline material includinggrains, which may be made of materials such as nitrides, oxides,carbides, borides, oxynitrides, diamond, and a combination thereof.Further, the bodies can be essentially free of an organic material,essentially free of rare earth elements, and essentially free of iron.The bodies may be essentially free of nitrides, essentially free ofchlorides, essentially free of nitrides, or essentially free ofoxynitrides. Being essentially free is understood to mean that the bodyis formed in a manner to exclude such materials, but the body may notnecessarily be completely free of such materials as they may be presentin trace amounts or less.

Certain features, for clarity, described herein in the context ofseparate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, may also be providedseparately or in any subcombination. Further, reference to values statedin ranges includes each and every value within that range.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

The specification and illustrations of the embodiments described hereinare intended to provide a general understanding of the structure of thevarious embodiments. The specification and illustrations are notintended to serve as an exhaustive and comprehensive description of allof the elements and features of apparatus and systems that use thestructures or methods described herein. Separate embodiments may also beprovided in combination in a single embodiment, and conversely, variousfeatures that are, for brevity, described in the context of a singleembodiment, may also be provided separately or in any subcombination.Further, reference to values stated in ranges includes each and everyvalue within that range. Many other embodiments may be apparent toskilled artisans only after reading this specification. Otherembodiments may be used and derived from the disclosure, such that astructural substitution, logical substitution, or another change may bemade without departing from the scope of the disclosure. Accordingly,the disclosure is to be regarded as illustrative rather thanrestrictive.

The description in combination with the figures is provided to assist inunderstanding the teachings disclosed herein. The following discussionwill focus on specific implementations and embodiments of the teachings.This focus is provided to assist in describing the teachings and shouldnot be interpreted as a limitation on the scope or applicability of theteachings. However, other teachings can certainly be used in thisapplication.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a method,article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such method, article, orapparatus. Further, unless expressly stated to the contrary, “or” refersto an inclusive-or and not to an exclusive-or. For example, a conditionA or B is satisfied by any one of the following: A is true (or present)and B is false (or not present), A is false (or not present) and B istrue (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural, or vice versa, unless it is clear that it is meantotherwise. For example, when a single item is described herein, morethan one item may be used in place of a single item. Similarly, wheremore than one item is described herein, a single item may be substitutedfor that more than one item.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent not described herein, many details regarding specific materialsand processing acts are conventional and may be found in reference booksand other sources within the structural arts and correspondingmanufacturing arts.

Many different aspects and embodiments are possible. Some of thoseaspects and embodiments are described herein. After reading thisspecification, skilled artisans will appreciate that those aspects andembodiments are only illustrative and do not limit the scope of thepresent invention. Embodiments may be in accordance with any one or moreof the embodiments as listed below.

EMBODIMENTS

Embodiment 1. A shaped abrasive particle comprising a body including afirst surface, a second surface, a side surface extending between thefirst surface and second surface, and a flange portion extending fromthe side surface and the first major surface.

Embodiment 2. The shaped abrasive particle of embodiment 1, wherein theflange comprises a rounded shape.

Embodiment 3. The shaped abrasive particle of embodiment 1, wherein theflange comprises a length that is less than a length of the body.

Embodiment 4. The shaped abrasive particle of embodiment 1, wherein theflange has a height that is not greater than a thickness of the body.

Embodiment 5. The shaped abrasive particle of embodiment 1, wherein thebody comprises a single flange and wherein the single flange extendsfrom the body and extends for a distance of not greater than 50% of atotal peripheral length of the body.

Embodiment 6. The shaped abrasive particle of embodiment 5, wherein thesingle flange extends around at least 1 exterior corner and not greaterthan 3 exterior corners.

Embodiment 7. A shaped abrasive particle having a body including a firstsurface, a second surface, and a side surface, wherein the bodycomprises a gear-shaped two-dimensional shape including a plurality ofteeth extending peripherally from the side surface of the body.

Embodiment 8. The shaped abrasive particle of embodiment 7, wherein theplurality of teeth extend along a length of the body.

Embodiment 9. The shaped abrasive particle of embodiment 7, wherein theplurality of teeth extend along an entire length of the body.

Embodiment 10. The shaped abrasive particle of embodiment 7, whereineach of the teeth of the plurality of teeth comprises a two-dimensionalshape.

Embodiment 11. The shaped abrasive particle of embodiment 10, whereinthe two-dimensional shape is symmetric about at least a bisecting axis.

Embodiment 12. The shaped abrasive particle of embodiment 10, whereinthe two-dimensional shape is asymmetric about a bisecting axis.

Embodiment 13. A shaped abrasive particle having a body including afirst surface, a second surface, and a side surface extending between afirst surface and the second surface, wherein the first surfacecomprises raised portions extending from exterior corners of the bodyalong the first surface and joining in a center region of the firstsurface.

Embodiment 14. The shaped abrasive particle of embodiment 13, whereinthe raised portions extend linearly from the exterior corners to thecenter region, and wherein the raised portions define and separate aplurality of depressed regions that abut the raised portions and atleast a portion of the side surface of the body.

Embodiment 15. The shaped abrasive particle of embodiment 13, whereinthe second surface comprises raised portions extending from exteriorcorners of the body along the first surface and joining in a centerregion of the first surface.

Embodiment 16. The shaped abrasive particle of embodiment 15, whereinthe raised portions of the first surface and the second surface havesubstantially the same arrangement relative to each other.

Embodiment 17. The shaped abrasive particle of embodiment 15, whereinthe raised portions extend linearly from the exterior corners to thecenter region, and wherein the raised portions define and separate aplurality of depressed regions that abut the raised portions and atleast a portion of the side surface of the body.

Embodiment 18. A shaped abrasive particle having a body defining apartial-ellipsoid shape, the body including a first surface, a secondsurface, and a third surface extending between a portion of the firstmajor surface and the second major surface, wherein at least a portionof the first surface and a portion of the second surface are connectedto each other along a first edge and wherein a portion of the firstsurface and a portion of the third surface are connected to each otherand define a second edge, and wherein a portion of the second surfaceand a portion of the third surface are connected to each other anddefine a third edge.

Embodiment 19. The shaped abrasive particle of embodiment 18, whereinthe first surface comprises a concave shape.

Embodiment 20. The shaped abrasive particle of embodiment 18, whereinthe first surface comprises a planar shape.

Embodiment 21. The shaped abrasive particle of embodiment 18, whereinsecond surface comprises a convex shape.

Embodiment 22. The shaped abrasive particle of embodiment 18, whereinthe third surface comprises a concave shape.

Embodiment 23. The shaped abrasive particle of embodiment 18, whereinthe third surface comprises a planar shape.

Embodiment 24. The shaped abrasive particle of embodiment 18, whereinthe first edge comprises a curved or elliptical contour.

Embodiment 25. The shaped abrasive particle of embodiment 18, whereinthe third edge comprises a curved or elliptical contour.

Embodiment 26. A shaped abrasive particle comprising a body having aconical or frustoconical shape, wherein a surface of the body comprisesa plurality of protrusions extending in a spiral pathway.

Embodiment 27. The shaped abrasive particle of embodiment 26, whereinthe body comprises a first surface, a second surface substantiallyparallel to the first surface and a side surface extending between thefirst surface and the second surface, and wherein the side surfacecomprises the plurality of protrusions.

Embodiment 28. A shaped abrasive particle having a body defining afin-shape, wherein the body comprises a length, a width and a thicknessand wherein the body comprises a rectangular cross-sectional shape inthe plane defined by the length and width and an ellipticalcross-sectional shape in the plane defined by the width and thickness,and wherein the aspect ratio of width-to-thickness (w:t) is at least2:1.

Embodiment 29. The shaped abrasive particle of embodiment 28, whereinthe body comprises a first surface, a second surface, and a sidesurface, wherein the side surface comprises two side surface portionscomprising a convex shape and two side surface portions comprising aplanar shape, and wherein the two side surface portions comprising theconvex shape are separated by the side surface portions having theplanar shape.

Embodiment 30. A shaped abrasive particle having a rake-shaped bodyincluding a first group of projections extending from a central regionof the body in a first direction and a second group of projectionsextending from the central region the body in a second direction, andwherein the first group of projections have a length (Lp1) that isdifferent compared to a length (Lp2) of the second group of projections.

Embodiment 31. A shaped abrasive particle having a body including afirst surface, a second surface, and a side surface, wherein the bodycomprises at least four distinct side surface portions separated by atleast four exterior corners, and wherein at least one side surfaceportion comprises a concave contour and wherein the particle comprises acurved shape, wherein the first surface comprises a substantiallyconcave curvature and the second surface comprises a substantiallyconvex curvature.

Embodiment 32. A shaped abrasive particle having a toothed bodyincluding a plurality of teeth extending from one side of the body,wherein the plurality of teeth define external corners of the bodyhaving an average spacing of less than 0.5(L), wherein L defines thelength of the body.

Embodiment 33. The shaped abrasive particle of embodiment 32, whereineach of the teeth of the plurality of teeth comprises a height andwherein at least some of the teeth have a different height compared toother teeth of the plurality of teeth.

Embodiment 34. The shaped abrasive particle of embodiment 32, whereineach of the teeth of the plurality of teeth comprises a height andwherein all of the teeth have a same height compared to each other.

Embodiment 35. The shaped abrasive particle of embodiment 32, whereinthe plurality of teeth are uniformly distributed around a peripheralsurface of the body.

Embodiment 36. The shaped abrasive particle of embodiment 32, whereinthe plurality of teeth are non-uniformly distributed around a peripheralsurface of the body.

Embodiment 37. The shaped abrasive particle of embodiment 32, whereineach of the teeth of the plurality of teeth define a single point on thebody.

Embodiment 38. The shaped abrasive particle of embodiment 32, whereineach of the teeth of the plurality of teeth define multiple points onthe body.

Embodiment 39. A shaped abrasive agglomerate having a body including aplurality of shaped abrasive particle portions bonded to each other toform the body of the shaped abrasive particle.

Embodiment 40. The shaped abrasive particle of embodiment 39, whereinthe body comprise a central hole extending through a thickness of theparticle.

Embodiment 41. The shaped abrasive particle of embodiment 39, whereineach of the shaped abrasive particle portions of the plurality of shapedabrasive particle portions have a triangular two-dimensional shape andwherein each of the triangles are joined to each other along an edge.

Embodiment 42. A shaped abrasive particle having a body including atleast a first surface, a second surface, a third surface, and a fourthsurface, wherein each of the first, second, third, and fourth surfacescontact at least one of the other first, second, third, and fourthsurfaces along at least one edge of the body, and wherein the firstsurface comprises a concave contour.

Embodiment 43. The shaped abrasive particle of embodiment 42, whereinthe body is in the shape of a pyramid with a tip and a base, and whereinthe first surface defines the base.

Embodiment 44. A method of making a ceramic body comprising: creating alayer of material from a mixture comprising a precursor ceramicmaterial; altering the surface of the layer with a gaseous or liquidmaterial to create a pattern in an upper surface of the layer; andforming the layer into abrasive particles, wherein at least a portion ofthe abrasive particles comprises a surface including at least a portionof the pattern created in the upper surface of the layer.

Embodiment 45. A method of forming a shaped abrasive particlecomprising: placing a mixture comprising a ceramic precursor materialinto a production tool comprising a plurality of openings, whereinplacing the mixture comprises partially filling a majority of theopenings of the plurality of openings.

Embodiment 46. The method of embodiment 45, wherein partially fillingcomprises placing the mixture into only a portion of the openings suchthat the openings comprise some mixture and some void volume that isfree of the mixture.

Embodiment 47. The method of embodiment 45, wherein partially filling amajority of the openings includes controlling at least one variable fromthe group consisting of: orientation of the plurality openings relativeto a direction of translation of the production tool; speed oftranslation of the production tool; viscosity of the mixture; pressureapplied to the mixture during placing of the mixture into the pluralityopenings; material of the production tool; surface energy between thesurface of the plurality of the openings and the mixture; and anycombination thereof.

Embodiment 48. A shaped abrasive particle having a body includingplurality of a discrete micro-voids distributed throughout the body,wherein the discrete micro-voids include a liquid or gas material.

Embodiment 49. The shaped abrasive particle of embodiment 48, whereinthe discrete micro-voids are non-uniformly distributed throughout thebody.

Embodiment 50. The shaped abrasive particle of embodiment 48, whereinthe discrete micro-voids are non-uniformly distributed throughout thebody including a greater content of the discrete micro-voids in acentral region of the body compared to a content of discrete micro-voidsat a surface region of the body.

Embodiment 51. The shaped abrasive particle of embodiment 48, whereinthe discrete micro-voids are uniformly distributed throughout the body.

Embodiment 52. A method of making shaped abrasive particles comprisingtranslating a production tool having openings over rollers and through adeposition zone configured to deposit a mixture into the openings,wherein in the deposition zone the production tool is translated over aprimary roller having a greater diameter compared to any other rollersin contact with the production tool.

Embodiment 53. A shaped abrasive particle having a multi-flanged bodyincluding a first shaped abrasive portion bonded to another shapedabrasive portion to form the body including at least two differentflanges, and wherein the different flanges extend in different planeswith respect to each other.

Embodiment 54. A shaped abrasive particle having an annular bodycomprising a first surface, second surface, a third surface extendingbetween the first surface and second surface, wherein the annular bodycomprises a rounded contour, a central opening extend through the body,and wherein at least a portion of the first surface comprises anon-planar contour.

The above-disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments, which fall withinthe true scope of the present invention. Thus, to the maximum extentallowed by law, the scope of the present invention is to be determinedby the broadest permissible interpretation of the following claims andtheir equivalents, and shall not be restricted or limited by theforegoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law andis submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. In addition, inthe foregoing Detailed Description of the Drawings, various features maybe grouped together or described in a single embodiment for the purposeof streamlining the disclosure. This disclosure is not to be interpretedas reflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may be directed toless than all features of any of the disclosed embodiments. Thus, thefollowing claims are incorporated into the Detailed Description of theDrawings, with each claim standing on its own as defining separatelyclaimed subject matter.

What is claimed is:
 1. A method of making a shaped abrasive particlecomprising: forming a mixture; disposing the mixture into a plurality ofopenings of a production tool, wherein disposing includes overfilling aportion of the openings of the production tool with the mixture;removing the production tool and creating precursor shaped abrasiveparticles, wherein a majority of the precursor shaped abrasive particlescomprise a flange from the overfilling of the mixture.
 2. The method ofclaim 1, wherein the mixture comprises a ceramic material and a liquid.3. The method of claim 2, wherein the ceramic material comprises anoxide, a nitride, a carbide, a boride, an oxycarbide, an oxynitride, anda combination thereof.
 4. The method of claim 2, wherein the ceramicmaterial comprises alumina.
 5. The method of claim 1, wherein themixture comprises a solids content of at least about 25 wt % and notgreater than about 75 wt % for a total weight of the mixture.
 6. Themethod of claim 1, wherein the mixture comprises a liquid content of atleast about 25 wt % and not greater than about 75 wt % for a totalweight of the mixture.
 7. The method of claim 1, wherein the mixturecomprises a storage modulus of at least about 1×104 Pa.
 8. The method ofclaim 1, wherein the mixture comprises a viscosity of at least about2×103 Pa.
 9. The method of claim 1, wherein the mixture comprises notgreater than about 30 wt % organic material for the total weight of themixture.
 10. The method of claim 1, wherein each of the plurality ofopenings of the production tool have a two-dimensional shape as viewedin a plane defined by the length (l) and width (w) of the productiontool.
 11. The method of claim 10, wherein the two-dimensional shapecomprises polygons, ellipsoids, numerals, Greek alphabet letters, Latinalphabet letters, Russian alphabet characters, complex shapes includinga combination of polygonal shapes, and a combination thereof.
 12. Themethod of claim 10, wherein the two-dimensional shape comprises atriangle.
 13. The method of claim 1, wherein each of the plurality ofopenings of the production tool have a different two-dimensional shape.14. The method of claim 1, wherein the production tool comprises acontinuous belt, wherein the continuous belt is translated over rollersto facilitate a continuous molding operation.
 15. The method of claim 1,wherein disposing comprises applying a force onto the mixture within adie in an application zone and extruding the mixture through a dieopening into the production tool.
 16. The method of claim 15, wherein aportion of the openings are positioned outside of the application zoneto allow a portion of the mixture to be extruded through and out of theopening to form precursor shaped abrasive particles comprising a flange.17. The method of claim 1, wherein the precursor shaped abrasiveparticles comprising a flange includes a body including a first surface,a second surface, a side surface extending between the first surface andsecond surface, the flange extending from the side surface and the firstsurface and wherein the body comprises a narrow end, a wide end, and aconvex portion wherein the flange extends from the narrow end and theconvex portion of the body.
 18. The method of claim 1, wherein theflange comprises a rounded shape.
 19. The method of claim 1, wherein theflange comprises a length that is less than a length of the body. 20.The method of claim 1, wherein the shaped abrasive particles formedaccording to the method of claim 1 are incorporated into a fixedabrasive article.